How to make a wood panel for acrylic painting

I don't recommend making your own panels. While I learned things creating a panel, it isn't cost-effective or the best use of my time. 

• Jerry's Artarama sells 18x24 inch wood panels for ~$33. The panels are offered in many sizes.

• Creating a wood panel takes several hours.

• The materials cost much more than $33. (Birch plywood ($11), poplar boards for cradle ($24), 4 hardwood dowels, acid free glue)

• The archival quality of Jerry's wood panels is difficult to replicate. 

Overview

• I am retired, and in my retirement, I am going to focus on doing the things I want, such as, painting. Most of my art to date has been copies of other's work. Going forward, I am going to focus on original works.

• Canvas is ideal for a very large painting or for paintings that need to be transported. 

• The oldest paintings were done on panels.

• The goal is to make an archival panel, which won't negatively impact the painting.

• I prefer the rigidity and texture of a smooth surface provided by a properly created panel.

• Jerry's Artarama sells panels in various sizes.

• if the panel is not going to be framed, then it requires an internal frame for hanging.

Why Custom Frames are Required:

• One reason I wanted to make my own panels is to minimize my costs in retirement. And I was hoping to avoid the cost of custom framing on every painting. However, this is problematic.

• I struggle to make a painting that fits a stock frame unless I pick out the matte and frame in advance. 

• A stock frame's inside is exact measurements. The frame's lip is 3/8 inch.

• The issue of using a stock frame arises from the mattes. The matte has random measurements, which guarantees a custom frame. I went to several framing shops and took measurements. I found the same issue at each shop.

• A matte has two dimensions of interest: the lip and the width (or the part between the frame and the painting).

  • The matte width ranges from 1-3/4 to 5/8.

  • The matte lip is non-standard, and ranges from a bit less than 3/8 to a bit longer than 3/8s.

• I like the look a matte adds to a painting. 

Parts 

• Birch plywood 2’x4’x1/4” project boards at Lowe's

• Poplar 3/4' x 1-1/2' x 8'

• 1/4 hardwood dowel rod

• Acid free wood Gorilla Glue

• 2x 1/4 #20 coarse 1-1/2" tapered bolts and nuts

• 2x 1-1/4 wood screws

• Index card

• Scotch tape

• Paper towels

• Blue painters tape

Tools

• Rotary sander and very fine sandpaper

• Table saw with blade that has at least 200 teeth

• Power Drill with 1/4 wood drill bit and counter sink bit

• Small hand saw

• 4x corner clamps

• 4x hand clamps

• Spring clamps

• Hammer, Phillips head screwdriver, Xacto knife, sharp wood chisel, measuring tape, sharpened pencil, small flat pull-saw

Part A. Create a jig to cut overlapping corners

• Each wood canvas requires 8 overlapping corner joints.

• To make these overlapping joints repeatable, create a jig.

Part B. Make the Cradle

Step B1. Cut supports to size

• Cut the poplar supports to size. 

Step B2. Create an overlap joint

• I use an overlap joint instead of an angled join

• Lower the table saw blade to 3/4"

• Cut the overlap (3/4" x 3/4") notch at the end of each piece of poplar

  • Use the jig to cut the overlaps

  • The 3/4" side of poplar boards will be glued to the birch plywood

Step B3. Drill hole for dowel

• Add corner clamps

• Drill 3/4" hole in corners

• Cut 3" pieces of dowel rod

Step B4. Glue 

• Loosen a corner clamp

  • Using a small brush, spread the glue on the overlap

  • Put some glue in the dowel rod hole

  • Using a hammer, pound a 3" piece of dowel rod into the hole

  • Tighten the corner clamp

  • Wipe off excess glue with a damp paper towel

• Repeat for the other corners

• Wash brush

• Let dry for 24 hours

Step B4. Dowels

• Remove corner clamps

• Saw off the excess dowel rods

• Use a chisel or orbital sander to remove excess glue

Part C. Attach plywood to cradle

Step C1. Cut 1/4" birch plywood to size + 1/4 inch

• Mark approximate location of cuts

• Wrap blue painter's tape around plywood where cuts are to be made

• Remeasure and mark on blue tape

• Cut on table saw

Step C2. Glue

• Spread glue on top of supports with a brush

• Place plywood and use hand clamps too apply pressure and keep the plywood from moving

• With a damp paper towel wipe off excess glue

• Let dry for 24 hours

• Use a chisel to remove excess glue. Hand saand if necessary

• Do not use an orbital sander on the birch plywood or its edges. It will take off the birch layer

Step C3. Trim to size

• Use a fluch router bit to trim to size