Started by cutting some 2x4s down to length of 24" long.

Run them along the table saw to get rid of the rounded aspect of the 2x4s.

Using a "jointer" board for my tablesaw, I "square" up the boards

Using a "jointer" board for my tablesaw, I "square" up the boards

After the boards were all squared, I cut them down to 1" strips. So the flag itself will be 13"x23.75"x.75"

Wiped them all down with Mineral Spirits to remove dusts and let them dry.

Took my propane torch and did some light torching. 

Here I just cut some thin strips to use as backers for the flag.

For this flag, I tried a different approach to the staining process. Instead of staining AFTER it's been glued up, I stained the boards before hand.  I think this worked better. 

Here is it all glued. What's not pictured is after the glue is dried I took it back to the tablesaw and trimmed up the edges. 

Time for the fun part. Using a dremel it is time for the Union! Having a Flex Shaft makes this a lot easier than trying to hold the dremel tool itself.

The template is the same template I've used in the past, I got it off of Amazon for a few bucks. 

Almost done. 

All done, after about 2-3 hours, the Union is completed and I am ready to move to the finishing stage.

Using Semi-Gloss spray poly gave it a couple of coats. 

All Done! Brought it inside the house to dry. 

Looks pretty nice. 

Close up shot of the Union.