The construction of the Nativity Scene started with a kit which was purchased from Scroll-saw Projects.

Jerry was very impressed by the “Life Like” design and the great colors which were used.  The kit was very economical and was the less expensive part of the project. Jerry has listed below the steps taken to achieve this great display which will last for years to come.

• The kit purchased from Scroll-saw Projects contained the printed designs of the images for each character and animal.  These images are captured on a heavy grade poster paper shown as a cut out.
• The images were cut out using scissors and leaving about an inch and a half of paper outside the outer edge.  This will be explained later why this is important.
• Next was to use a construction material which would provide a smooth surface for a great finish as well as durability in outside weather conditions.  This was achieved by purchasing ¼” Luan (Hardboard).  This material is not used directly in outside applications, but can be if prepared correctly.  To determine how many sheets, take all of the sheets of images in the kit and lay them out to calculate the total 4’ x 8’ sheets needed.
• Paint these 4 x8 sheets of Luan with an oil based primer, on both sides.  Allow them to dry for a least a day, before proceeding.
• Next you want to paint all areas with a good grade of exterior white paint (water based preferred), Gloss or Satin. 
• The cut out images are then placed on the Luan, and taped down with a couple of pieces to prevent movement.
• A Sharpie marker is used to trace the images on the board. Number each image with a pencil on the edge and the matching image on the board.  This makes is easier when it comes to locating the matching pieces.
• Use a scroll or jig saw to cut out each image.  Accuracy is not as important at this stage of the process as it will be later on in the later steps.
• In order to provide additional stability to the board and to create some way to mount the characters for display, additional construction materials are needed.  The use of 1” x 4” # 3 grade pine will work just fine.  Measure the length or height of each of the characters.  Total these numbers and purchase a few feet over for assurance of having enough, if a mistake is made.  Be sure to allow for two supports on the larger figures. Only measure from three inches inside of each edge.  The legs to mount the figurines will be discussed later.  
• Paint all of the 1” x 4” lengths with an oil based primer.  Don’t worry about the edges after we cut, we will prime those later.
• Next you want to paint all areas with a good grade of exterior white paint (water based preferred)  
• Measure and cut your support members for each character.  Be sure to cut the edges, which will be exposed to the elements, with a 45 degree angle.  This will assist in water run off from the wood.  On some of the larger characters, use two tall supports and smaller cross sections.  Be sure to number each of these to match your character for easy identification upon assembly.
• Attach the support members to the back side of your cut out Luan pieces.  Use small wood screws and Liquid Nail adhesive, in a tube. 
• Next step is the gluing of the paper designs to the front side of the Luan.  This is a very important step and can be incorrectly performed, if not careful.   Use water-based or resin-based glue and may need to be thinned out with a little water before application.  Place a thin coat on the primed front surface of the Luan.  Place the cut out poster on the area and use a damp cloth to press out the paper, to remove wrinkles.  If you have a large bubble area, then use a razor to slice across that area and overlap the two pieces together. Allow these to dry for about 24 hours before starting the next step.
• Use a jig saw with a small tooth blade to cut out the figures along the edges.  Leave about a ½ inch of area outside the design of the paper.  This will be explained next.
• Take an orbital sander to round the edges which were cut.  This will serve two purposes: Keep from the edges from chipping; allow water to run off.
• Paint the edges just cut and the edges of the support members on the back with the Oil Based Primer.  Allow 24 hrs before the next step.
• Paint the ½ inch area around the design and the outer edge of the Luan with a flat black oil based paint.  Then paint the edges of the support members with the white exterior paint.  Allow about three days of drying before the next step.  Be sure to store these away from humid areas.
• In order to protect the image from fading and weather conditions, a good protective coating will need to be used.  It is recommended that a coating material such as, Hydrocote- Polyshield Clear Satin, be used to provide the best coverage.  A lot of time is invested in this project, so you want to provide the best protection.  This can be located by clicking here.
• The instructions indicate to place at least 3 separate coats on the area. Recommendations are to use 3 or more.  Be sure to allow each coat to dry completely in a dry area, before applying each coat.  Paint ALL wooded areas, including the back-side of the characters and supports.  This special coating has a UV protector and will not yellow, like other over the counter products. DO NOT stack these on top of one another.  The coating takes a few days to cure and will pull the image and paper away when you separate them.
• The next final step is to create some supports to hold the figures in an upright position.  ½ inch metal EMT (electrical conduit) was used.  You can use rebar if you prefer.  To clamp my upright supports to the back of the figures, ½ inch conduit clamps were used.  The clamps were attached to the upright supports, using ¾ inch wood screws.  Two small supports on the bottom were used to raise the figure above the ground by 4 inches and use one support angled at 45 degrees from the top side down to the ground behind.  On the larger figures, two supports were used.

Now it is time to really enjoy your project for years to come.  Be sure when storing these works of art after Christmas, that each one is separated.  This will prevent heat from causing the coating to stick to one another