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To make the dough: In a large saucepan, heat the buttermilk and butter until the butter is just melted; remove from the heat.
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Add the brown sugar and molasses, then beat in the egg.
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Whisk the baking soda, spices, and salt with 1 cup of the flour.
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Add this to the wet mixture and mix until incorporated.
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Add flour 1 cup at a time until you have a smooth, stiff dough. It should be stiff enough to be flexible, and neither crumbly nor sticky.
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Divide the dough in half, flatten each half, and wrap in plastic. Refrigerate for at least 1 hour.
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Preheat the oven to 350°F.
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Using a quarter of the dough at a time (return the unused portion to the refrigerator), roll the dough 1/8" thick on a piece of parchment.
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Cut your construction pieces as needed, pulling away the scraps to be re-rolled. Transfer the dough, parchment and all, to a baking sheet.
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Bake the dough for 10 to 12 minutes, until set and very lightly browned at the edges.
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Remove from the oven and trim any rough edges while the pieces are still warm. Cool completely before using for construction.
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To make the royal icing: In a large bowl, whip the egg whites with the cream of tartar until foamy.
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Sprinkle in the sugar gradually, whipping all the while. The more you whip the icing, the stiffer it'll be and the faster it'll harden up.
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Cover the bowl of icing, taking out only as much as you'll need immediately. The easiest way to store the icing for long periods of time is in a plastic pastry bag, or zip-top food storage bag.