Good luck with that, Rightarm! It sounds like a worthy project for sure. The woodburning idea sounds good too.
There's lots of good advice in this thread. I don't know how to make a pattern but it sounds like you do. I still find most portraits to be quite intimidating but these were fairly simple. I like to take my learning in small doses (and I did learn a lot from doing these). Good luck again. Please be sure to post pics!