How to Make a Custom Wood Cross | EASY DIY Woodworking Project

March 11, 2021 Matt Outlaw

I wanted to build a unique looking wood cross so I started looking around the internet for inspiration. I came across Dennehey Design’s layered crosses and thought they were absolutely beautiful and a genius design. So I set out to make something similar, but put my own spin on it.

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I really didn’t have a clear idea of exactly what I wanted to do. And that probably comes out in the video (linked below) as you see me arranging the wood pieces in a variety of ways. I came up with a design pattern that I liked and glued it all together. After the glue up I started thinking it needed something more. So, thinking back to my mallet build video, I knew I wanted to inset a gold John 3:16 coin in the cross.

While making the video, I also wanted to give another design option and have been seeing the American Flag crosses were gaining popularity. I always liked the looks of them so I thought I could make one on video as well. I set the Fallen Officer’s coin in this one. I actually looked around locally for a set of wood stars to put on the cross like others are doing. But no one in my area had any and I didn’t want to wait to have some shipped as I wanted to get the video done and out to you guys. So, naturally if I was setting a coin in the other cross, why not this one as well. It is a great way to honor the fallen officers for their sacrifice as well as the sacrifice that was made on the cross.

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CUT LIST FOR AMERICAN FLAG CROSS:

6 pieces 3 1/4” x 1 1/2” for the bottom stripes.

2 pieces 4 1/8” x 1.5” for longer stripes beside union.

1 piece 3 1/2” x 3 1/4” for top union (top blue piece)

1 piece 7 1/4” x 3 1/8” for left blue piece.

You’ll need a 2” forstner bit if you want to use the same coin as I used for the inset.

The back of the American flag cross I used 1/4” plywood. I suggest using at least 1/2” plywood to make it more ridged. The 1/4” seems to flex too much for my liking.

CUT LIST FOR EXOTIC WOOD LAYERED CROSS

Downloadable PLANS available here https://www.731woodworks.com/store/layeredcrossplans

For the main cross that was half lapped, I used yellow heart or mora wood.

1 piece 20” long by 3/4” wide. (see video for half lap point)

1 piece 11 1/8” long by 3/4” wide.

For the side pieces I used Purple Heart.

2 Pieces at 13 3/8” long by 1” wide, length is from the 45 degree tip to the square cut

6 pieces at 4 3/8” long by 1” wide, length is from the 45 degree tip to the square cut

For the flat pieces on top of the Purple Heart I used blood wood.

2 pieces at 8” long x 7/8” wide

6 pieces at 2 1/2” long by 7/8” wide

For the top cross pieces that is on top of the yellow heart I used blood wood again.

1 piece at 15 1/8” long x 3/8” x 7’8” I set this on end grain so it stood vertical.

1 piece at 9” long. I half lapped this piece as well but the forester bit cut the half lap out so that step isn’t necessary if you are insetting a coin like I did.

Forstner bit used for gold John 3:16 coin is 1 5/8” which is slightly larger than the coin.

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