It all starts with Richard Holdman's idea: http://www.holdman.com/christmas/star/ But I didn't want one quite that big. So I first decided to make one with C7 bulbs instead of C9's. From there I drew out the plan and figured out about where the lights should go and how many I was going to need. From there I figured out what size the star should be and so off I went!
I pretty much followed his plans and making it. However, since mine was smaller and I didn't use the same thickness board, I had to figure out those details on my own.
I first got a piece of 3/8" plywood about 3ft by 4ft. I then used a projector to cast the pattern on the board and traced the pattern.