I had some leftover pieces of pallet boards from this and this project, and decided to put the scraps together to make an American Flag. I grabbed a bunch of pieces that were the same thickness and cut them all to the same length with a chop saw. I designed the flag to be constructed in three separate panels, measuring everything with an effort to keep the flag fairly close to the accurate proportions.
I painted all the boards with some white paint (slightly watered down to give it a white washed look) then taped off the sections for the red stripes with painters tape.
For the stars I created a paper template and traced all the star outlines onto the white background. To fill in the background I carefully painted in two coats of the deep blue around the white stars.
Once all the paint dried I went back over the flag with the orbital sander to give it a little bit of a worn look.
The total cost for this pallet wood American flag project was about $15 for paint. And about 6 hours of my time.