How-to
Well i did my Pai-Sho Board making a square of 50 centimeters each side and the pieces of 2 centimeters of diameter. I made my own design of the pieces but having in mind that each design have to be perfect with symmetry. I made the game for two players: One with the flowers with white back and others with black back. All my pieces and the board are made of wood. (The picture is from other's game).
Pictures
A Pai Sho board in the making. It's made of plywood, and painted with acrylic paint. Oh and feel free to use the picture if you like :).
Here are some Pai Sho pieces made by Thomas:
They are laser-engraved plywood, hand-colored with Sharpie markers, which bled just a little. They're 1.5 inches in diameter, which would require at least a 27-inch board to play on. These may be all the designs that we actually see in episodes of Avatar, but Thomas may have missed a few.
User - Jeremy:
I have made a set of Pai-Sho Tiles using the actual flower designs as opposed to canon tiles, but the gameplay will essentially be the same. I made these using 1 1/2-inch wooden nickels and sharpie markers. I made up the designs in Photoshop and transferred the designs onto the tiles using tracing paper and then filled in the areas with the markers.
There are 13 total tiles in the set. Shown from left to right, from top to bottom:
Boat, White Jade, Wheel, White Dragon, Reversal(my original tile), Rock, White Lily, White Jasmine, Knotweed, Red Rose, Red Rhododendron, White Lotus, and Red Crystanthemum.
Print and Glue Board and Tiles
I created a full scale drawing and exported it to a PDF file which I brought to FedEx Kinkos.
They printed it in large format paper which I mounted on foam board and cut down to 24x24
For the tiles I had a wooden dowel cross cut on a table saw, I'm sanding and staining them now.
Stain Options
For the images I exported as a PDF and printed them at home
I added a guide for cutting shown here as the 1 inch circle.
I bought a 1 inch hole punch to use for cutting the paper.
Which I then glued to the wooden tile.
I'm making hundreds of these for different variants so I'm not finished yet. But I thought the process would be helpful to see.
How To
My Pai Sho board cost me just under $20 in raw materials, but I already had some stain required and I found the wood lying on the side of the road (how fortuitous, I know). I used a woodburning kit to do the grooves and grid.
The tiles were made by cutting and sanding a dowel and then woodburning and staining the pieces. Some turned out better than others, but all are definitely doable
The Result
The board isn't quite canonical because of the 2 white "ports" but that's because I like symmetry and because I make use of that in my variant: Ancient Pai Sho.