Well i've finally finished off another flag and will describe each step i took to do it.
Step 1:
The Design: I've designed the flag on Word and printed it off.

Step 2:
From the design, work out how big you want the flag to be. Having measured it to scale i've made the flag up. (i've not gone into detail with the sewing techniques as it's not that complicated for anyone to do)
The LetteringStep 3:
Working out the size of the letters: Knowing what lettering i want to put on the flag, i've measured the lenght of the Blue material to work out how big the letters can be.

I then printed off the word 'ULTRA' from the computer to a fairly large scale. I then measured the lenght of the word and worked out the ratio of that lenght to the lenght of the Blue material. With this ratio i can then work out what the hieght of the letters being used.
As these letters aren't that big, i'm able to print them off to the exact size on paper. To print them off to the exact size, i use just one letter and print it off however many times i need to, to work out the size of the font i need to use. I then printed off each letter which are of the exact size required:

Step 4:
Drawing the letters onto the bondaweb: Bondaweb is the stuff i use for all the flags i make. You can by it in department stores like John lewis. It's like a sheet of paper. But it has a 'smooth' side and a 'glazed' side. The 'smooth' side it to draw the shape on and the 'glazed' side is ironed onto the material being used.

You must first draw the letters out onto the smooth side of the bondaweb and then iron the bondaweb onto the material.
Dont forget: when drawing a letter on you must reverse it otherwise when you stick/iron on the final product it'll be back to front!
So, with the letters i've printed off i need to draw them onto the bondaweb. In order to help me draw them on, i've made a light box which helps reverse the letter. I've simple turned the paper over and able to see the letter to be drawn:

Having cut off enough bondaweb to draw all the letters on from the roll, i started to draw the letters on:

and here's the result:

Now cut roughly around all of the letters, do not cut along the outline of the letters!!:

Step 5
Ironing the bondaweb onto the materail used for the letter: I'm using a white material for the letters. The reason to cut all the letters out roughly is to make it easier to iron onto the material. Place the letters onto the material with the 'glazed' side facing down. Iron over the bondaweb for roughly 10sec. Then iron on all the letters.

Roughly cut out the letters again from the material. The bondaweb must remain where it is on each letter. Now cut out the letter from the materail using the lines that have been drawn on. Once you've cut them out, line them up onto the material that they'll be going onto:

Using a ruler or something else with a long straight edge, position the letters in exactly the correct position, this may take time.
Once you're happy with where they are, 1 by 1 remove the letter from it's position and peel the 'smooth' side of the bondaweb off the letter (which will leave just the 'glazed' side on the letter). Then place it back into position. Once all the letters have been re positioned, you can start ironing them on.
To do this you need a damp cloth. With the damp cloth, drape it over the letters and then iron over it. Spend at least 30 seconds ironing the cloth for the best results. Once you've finished the ironing, take the cloth off and you should see the letters fairly damp all over. This is normal, all you need to do then is go over it again with the iron (without the cloth) and dry it out. If you find some parts of the letter have not stuck to the flag material, simply do this whole process again.
Once this has been completed it should look like this:
The imageStep 6:
Having chosen the image i want to use, i've printed it off.

As i want the image bigger than it can be printed off on A4 paper, i'll have to blow the size up a different way.
You can do this 2 ways: 1) by measuring every point on the smaller scaled picture and then scale it up and draw it free hand onto the bondaweb, or 2) use an overhead projector.
I'm using an ohp as it's much easier. Although i dont have any see through sheets to print it onto at the mo (which are used on ohps) i've just cut out all of the white parts of the image:

This can now be used on the ohp. I've set the ohp up projecting the image onto a wall. You may have to adjust the distance of the ohp from the wall to make it to the size you want. I'm making the projected image to the biggest size possible that i can draw onto the bondaweb:

Once it's set at the required size, i've cut the sufficient amout of bondaweb needed for the image. Then i've stuck it to the wall using masting tape:

Then draw around the the image on the bondaweb. This is the result:

I've also had to do a second one of just the outline of the shape. This because i'm using both black and white.

I've then taken these 2 bits of bondaweb and ironed them onto the material that is required for them (details of how to iron them is above):

Once the bondaweb is ironed on, cut the shapes out. The aline them onto the flag into the position that you wish it to be. Then take them off and peel the 'smooth' side of the bondaweb off the image. Then using the cloth again, iron onto the material (details of how to iron them is above as well):

And the image has come out like this:

So after all that, i now have a 2-stick which looks like this:

If you want to use bigger letters or images, simply (by using the ohp) stick bits of bondaweb next to each other on the wall to cover the image that's required.
If there's anything you dont understand or want more help, please let me know. I know i've gone on a bit but i hope i've explained it as fully as as i can!
This 2-stick isn't quite finished yet as the guy i'm making it for wants a few more bits here and there, i should have it completed by tonight.
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!FLAGBOY! - RedBlueArmy -
UltrasUK