Measure 2” from the exact center of the “X” shape on four sides to create a square shape around the center of the “X”. Cut out the template as one piece, making sure not to cut into the square shape.
Use a drafting compass to easily draw a 2”-diameter circle onto the plywood. If you have a jar or can whose diameter is 2”, you could also use it to trace the circle. It is best to trace all the pieces you need onto the plywood before you start cutting. This way you make sure that you have laid out the pieces efficiently and have enough wood to complete your project. Do not use “chipboard” or MDF as it is likely to fall apart when it becomes wet. [1] X Research source
Circular saws are faster than jigsaws for long, straight cuts, but they cannot produce small shapes. If you have both, use a circular saw to cut out the sides and a jigsaw for the other pieces.
If you use paint, choose an outdoor latex paint. If you use stain, follow it with at least one coat of clear polyurethane in order to provide weatherproofing.
Place a pencil between these pieces and push the wood together to form a gap the width of the pencil. Repeat this process with the remaining side pieces until you have laid all six side by side.
If the body is not level, mark which piece(s) are too long and sand them down to stabilize the body. Sand gradually and check your work often.
Once the glue is dry, use a small chisel to scrape away the excess glue.
Do not use MDF or chipboard as it will not hold up in outside weather.
Drill a ⅛” hole in the center of the circle. This should be the spot where all the lines you just drew intersect.
To give the circle stability as you cut, you will probably want to clamp it to a worktable or large piece of wood set on two sawhorses. Move the clamp as needed.
Once the glue has completely dried, you can use a chisel to remove any excess glue.
Place a ruler or straightedge at the top of the square 2” from the outer edge of the square. Tilt it to a 45-degree angle. Use a pencil to draw a straight line from the top of the square to the outer edge of the square. This should create a triangle shape. Repeat on the other side.
You can wait to paint or stain the whole thing until it’s fully assembled, but that may be more difficult.
Don’t attach the windmill too tightly. It should be secure, but still loose enough to allow complete rotation of the circle.
You can also use the rest of your wooden dowel as the post. Most dowels sold at hardware stores come in 48” lengths, so you should have about 32” remaining after you cut off the boom.
