Step 1: Download and print out the PDF frame pattern, then mount the copy on a piece of 3/8" thick Baltic birch plywood using spray adhesive (see Photo 1).
Step 2: Now drill entry holes in all the cutouts (see Photo 2). An old scroll-sawing tip is to drill tiny holes using a #20 finishing brad held in a small chuck. This will help you avoid the tearout you might get using regular drill bits.
Step 3: A #2 scroll saw blade with about 20 teeth per inch is ideal for cutting the frame pattern (see Photo 3). This blade is so fine it can make the smallest turns and never require you to back out of any cuts. It also leaves a very smooth edge that doesn't need sanding. An old hand at the scroll saw might only use one blade for the whole project, but you should have a few blades on hand, just in case! After the sawing is completed, soak the frame in mineral spirits for a few minutes to loosen the paper pattern, and carefully peel it off. Be sure to wear rubber gloves.
Step 4: Now rip 1/4" x 1/4" birch strips to make the rear framework and sand them smooth (see Photo 4). Miter the ends of the strips to fit on the back of the fret sawn frame, leaving a 5" x 7" opening for your pictures. Spread a little yellow glue on each strip and hold them in place until the glue sets.
Step 5: Once the glue dries, sand the faces and outside edges of the frame to 220-grit. This frame was stained with a fruitwood color to give it an older, antique look. Since brushing on a finish would be difficult, we recommend Deft Clear Finish in a spray can (available at rockler.com). In a well-ventilated area, apply three coats, making sure to cover all the surfaces and spraying from many different angles to reach all the nooks and crannies.
Step 6: Now you can add the turn buttons (see Photo 5) and the hanger. These items, along with glass and matboard, are available at local hardware stores. Once the hardware is set, complete the frame with your favorite photograph.