I had some left over 100 year old reclaimed barn wood scraps under the work bench and for some reason I thought those might make good light switch covers. The thing is they were a little under 4/4 (1″ thick). I just ran them over the table saw in 2 passes and cut them in half. The back was softer wood than the front – and the front was painted red (faded). I just ran some ebony stain over all – and you see some turned out black and some a maroonish black.
I basically just used an existing light cover for the template to get the size and lining up of the screw holes. The only thing is that these site about 1/8″ from the wall despite the fact that I tried to slightly route out the backside for the edge of the switch box in the wall. Now that these have been on my kitchen walls for a few months, I think if I were to try it again I’d do it a little bit differently. I may have copied the existing light switch cover size verbatim, but who’s to say it has to be that size? I think next time I’ll create a unique scroll saw design that’s bigger than the cover size. We’ll see what I come up with next time around, it surely won’t be standard.