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. 

• 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 want 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 cannot 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 eachhop.

• 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'. 

• Liquitex gesso.

• Golden Open Acrylics: Yellow Oxide, Burnt Sienna.

• 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.

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 supports

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 joint.

• 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 supports

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

• 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. Shellac

• Spray shellac on back of plywood to prevent moisture from entering plywood.

Part D. Gesso

Step D1. Apply gesso to front and sides of panel

• Spread gesso with a large (2-3inch) house painter's brush. 

• Tint (very light) each coat of gesso as follows: 

  • 1st is white, or just gesso.

  • 2nd is gesso lightly tinted with Yellow Oxide.

  • 3rd is gesso tinted with Burnt Sienna. When dry, the Burnt Siena tinted gesso should be the medium tone in the underpainting.

• Let dry for ~4 hours.

• Sand between each coat of gesso.