2. Enlarge the Uncle Sam pattern 130 percent, and duplicate it with tracing paper. Copy the outlines of Uncle Sam and two shoes onto 1-inch pine (actual thickness: 3/4-inches). Copy the banner, the three stars, and the flag onto 1/4-inch Baltic birch plywood. Cut out the shapes with a scrollsaw, using a #5 blade. Cut a 1/4 x 2-inch dowel in half. Drill all holes where shown on the pattern. 3. Sand all surfaces with 100- and then 150-grit sandpaper. Remove the sanding dust with a tack cloth. 4. For Uncle Sam's nose, roll a small piece of modeling compound into a ball, then flatten the ball slightly so it measures 1/4-inch in diameter. Let the nose dry (see the manufacturer's instructions). Attach the nose with tacky glue after you complete all painting.
1. Base-coat with 1/2-inch angular flat and #6 flat brushes, apply details with a #1 liner brush, and blush his cheeks with a 3/8-inch stencil brush. Continue the colors around the edges of the cutouts. Transfer the main pattern lines onto the cutouts. There's no need to copy the details yet -- you'll base-coat over them. 2. Base-coat Uncle Sam's face and hands MF; the sleeves, hatband, banner, and striped area of the flag SN; the vest NP; the pants and flat star field MB; the shoes and hat LB; and the stars HB. Let the paint dry and then lightly sand with a paper grocery sack to remove fuzz raised by acrylic paint. Remove the dust with a tack cloth. Now transfer the details. 3. Dip a stencil brush into NP, and wipe off most of the paint on a paper towel. Using a circular motion, blush Uncle Sam's cheeks. Dot his eyes LB. When the dots are dry, apply SN highlight dots. Dip the tip of a #1 liner brush into SN, and dab on his eyebrows. Dilute BS with water to ink consistency, and paint the lines on his ears. To apply his beard, alternate strokes of SN and NG; make sure the darkest area ends up under his mustache. Paint his mustache SN. 4. Float LB shading down the center of the vest where shown on the pattern. Paint or stencil the stars on the vest with HB. (Use the 5/8-inch stencil brush to stencil the stars.) 5. Paint the patch on his left sleeve HB. Dip a stylus into LB, and dot the patch. Paint the patches on his right sleeve MB and NP. Dilute LB with water to ink consistency, and apply the details and stitching lines to the patches. 6. Paint the checks on the pants LB. Dilute SN with water to ink consistency, and paint a line down the center to separate his legs. 7. Paint the stripes on the hatband and on the flag NP. Dot the MB area of the flag with SN. Paint or stencil the stars on the banner with HB. Then ink the letters and the stitches with a fine-tip permanent black marking pen. Using a stylus, dot the letters with LB.
1. To prevent the ink from smearing, spray the inked areas with Krylon 1311 clear acrylic spray. Let the spray dry. Apply your favorite antiquing medium to all surfaces of the cutouts. Let the antiquing medium dry. 2. Hammer three brads into the vest for buttons. Sand spots of paint from the hands, the banner, the shoes, and the two stars where the pieces join. Epoxy the banner to Uncle Sam and one star to each shoe. Let the epoxy set, and hammer a brad through each star. 3. Epoxy one end of a 1-inch length of 18-gauge wire into the bottom of the remaining star; epoxy the other end into the hat. Attach the flag to his hand in the same manner, using 4 inches of 16-gauge wire. Using the same technique, attach the shoes with the 1/4-inch dowels. Let the epoxy set. Spray all surfaces with Krylon 1311 clear acrylic spray, and let the spray dry.