Duplicate the sign and star patterns in the pattern packet with tracing paper. Using a tablesaw or a radial-arm saw, cut a 30 inch length of 1x6 pine (actual size: 3/4x5-1/2 inches) to a length of 24 inches for the sign. Copy the outline of the star onto the remaining pine. Using a scrollsaw with a #5 blade, cut out the star and cut the notch in the sign. Drill all holes where shown on the patterns.
Sand all surfaces with 100- and then 150-grip sandpaper. Remove the sanding dust with a tack cloth. Apply wood sealer to all surfaces, and let the sealer dry. Sand again, and wipe clean.
Use a 1 inch sponge brush to base-coat large areas. Paint design areas with #6 and #0 flat brushes, and apply details with a #10/0 liner brush.
Base-coat the Uncle Sam side of the sign LB and the Santa side BR. Paint the edges BR. Place the star on the sign to check for positioning. Remove the star and base-coat the Santa side and the edges of the cutout BR. Base-coat the top half of the Uncle Sam side of the star LB and the bottom half AW. Let the paint dry. Using white graphite paper, transfer the main pattern lines to each side of the sign and the star. There's no need to copy the star details yet-you'll base-coat over them.
Sign: Tape off and paint the ¼ inch border on each side DG. Paint the lettering AW. Let dry; apply another coat. Using a #0 flat brush, paint the letter shadows BR.
Uncle Sam: Base-coat his face PC, the hat AW, the hat brim LB, and his shoes RB. Paint the stripes on the pants and the hat BR. Paint the belt RB and the buckle DG. Dilute PR with water to ink consistency, and paint his cheeks. Dot his eyes RB. Paint the sleeve cuffs and his hair, beard, and mustache AW. Using RW, paint the stars on the hat brim, and apply highlight strokes to his hair, beard, and mustache. Dilute RU with water to ink consistency, and using a #10/0 liner brush, apply the line work under his mustache and across the top of his nose.
Santa: Base-coat his face PC. Paint the hat brim and the sleeve and pants cuffs AW. Paint the belt and buckle and his face, hair, beard, and mustache as far Uncle Sam. Paint Santa's eyebrows RW. Using a scruffy round brush, stipple PE foliage, followed by RW highlights. Dip a brush handle into PR, and dot the berries. When the dots dry, add smaller RW highlight dots.
Sand paint from some of the edges on each side of the sign and the star. Remove the dust. Apply your favorite antiquing medium to all surfaces of the sign and star. (Project designer Charlene Cooper used Miniwax Special Walnut Stain.) Let the medium dry.
Dilute RB with water to ink consistency. Dip a spatter brush or an old toothbrush into the thinned paint, and spatter (flyspeck) all surfaces of the sign and the star. Let the paint dry. Spray all surfaces of the sign and the star with two or more coats of satin-finish varnish, allowing ample drying time between coats.
Hammer two nails partway into the top edge of the sign where shown on the pattern. Form a 1-1/2 inch loop in the center of a 36- inch length of 19-gauge wire; twist it to secure. Curl each side of the wire hanger by wrapping it around a pencil, dowel, or paintbrush handle. Wrap the wire ends around the nails. Pound the nails in farther, if necessary. Epoxy one end of the dowel into the sign. Paint the remaining end of the dowel BR. When the paint is dry, slip the star over the dowel.