DIY Custom Outdoor Sign with BurnStencils®

DIY Sign - Custom, Weatherproof, & Fun!

Looking for a fun weekend project that adds personality to your outdoor space? This DIY outdoor sign is the perfect way to dress up your poolside railing, backyard shed, or patio with something custom and waterproof.

In this post, we’ll walk you through how to make a rustic wood sign from scratch using just a few basic tools and a little creativity. Whether you want to spell out a favorite quote, personalize something for your family, or just add some backyard charm, this project is super adaptable.

The end result? A weatherproof, mountable sign that brings character to your space and holds up against sun, splashes, and rain.

 

 

🧰 Supplies You’ll Need:

• Pallet wood or any reclaimed wood boards
• Saw (if needed to trim boards)
• BurnStencils®
• Butane torch & butane fuel
• Sandpaper or a sanding block
• Acrylic paint and/or paint markers
  
• Flat sponge brushes & small paint brushes
• Power drill/driver
• Wood screws
  
• Outdoor waterproof lacquer or clear coat spray

 

🔥 Step-by-Step Process

1. Cut Your Wood (if necessary)
Cut your boards to the desired length. Don’t worry about perfection, the charm is in the character! Slightly varying the lengths or purposely staggering the edges can give it a more handmade, rustic look.

 

2. Sand & Paint
Lightly sand the front of each board until smooth. Leave the boards you plan to burn bare. Paint the others using your chosen colors.

 

 

3. Burn Your Designs
Pick out your BurnStencils: letters, symbols, or full designs. Position them on your wood, then carefully torch over the stencil to burn the design into the surface. You can go light or dark depending on your desired look. BurnStencils hold up well to heat and leave behind a clean, crisp image.

 

 

4. Add Paint Accents
Once the wood cools, it’s time to add color and detail. You can use your BurnStencils again here, they’re not just for burning! Line them up and use acrylic paint or paint markers to fill in your designs. They work great as traditional stencils for painting clean, sharp shapes, or lettering.

Want more personality? Highlight the burned outlines with color, fill in the designs entirely, or freehand extra details. A fine-tip paint marker is perfect for crisp lines and small areas.

 

 

5. Secure the Back
After the front is complete and dry, flip the sign over and screw a couple of vertical boards across the back to hold everything together. This reinforces the structure and helps prevent warping.

 

 

6. Seal It Up
Spray the entire sign: front, back, and edges with a waterproof lacquer or outdoor clear coat. Apply a few light coats to protect it from sun and splashes.

 

 

💡 Tips:

• Test your burning technique and paint colors on scrap wood before starting.
• Slightly watered-down paint lets the wood grain show through for a more rustic effect.
• After burning, try brushing the whole board with a very watered-down paint or stain for added depth.
• Intentionally stagger your boards slightly, it gives the piece a more natural, handcrafted look.
• Before attaching the back support boards with screws, take a minute to pre-drill the holes. This helps prevent the wood from splitting and keeps everything looking clean.
• You can also add a bit of wood glue between the boards or under the support pieces on the back for extra strength and long-term durability.
• Always let your paint fully dry before applying sealant.
• This can be fun for the entire family, kids included, especially the painting! If you let them use the torch, teach proper safety techniques and monitor them the entire time.

 

This is a great weekend project and an awesome way to use BurnStencils to create something custom and lasting. It’s a creative DIY that really stands out.