I want to make wood signs like the State Parks have, big letters such as 4″ – 5″ high. Any ideas? I am looking at using a router with a 3/4″ core box bit. How can I do this without routing freehand? Is there a template machine out there? Should I consider building a one-to-one duplicator?
Thanks
Dario
Replies
I worked at a park and we went all around this one...finally decided to have a sign company supply graphics suitable for sandblasting; We rented a high quality sandblaster and let 'er rip...worked extremely well and they looked pro...hard to get that look with a router
regards,
silver
Silver,
What are the graphics made of of? Is it rubber? My neighbor had a large rock blasted for his street address and they used a rubber overlay. How much did it cost? How much did the blaster cost to rent?
Thanks.
Dario
Hi Dario,
If you want a sign that has gives you a high degree of creativity then sandblast.
A routed sign will always look like a routed sign no matter how fine the workmanship.
BTW, a student brought in a sign he had carved and blow me away totally.
Leaves carved in relief on the edges, his last name carved in relief with a fabulous finishing job...took him many hours...his style
What does the sign you see look like...from what I read, your style is routed.
have fun
silver
Edited 5/3/2005 12:57 am ET by silver
Used to make a lot of these for mobile BBQ smokers and house address signs.
Find the biggest set of letter temps you can find. I think I have 3", 4", and 5" temps that I found at Home Chepo. Lay out your sign on a piece of 1/4" MDF. Drill out the curved ends of the letters with a Forstner bit, and cut out the rest with a jig saw.
Get the largest PC template guide that will fit into the cut-out letters you have made, and cut off the flange so it doesn't protrude below the MDF. Install on you router, and use the largest flat bottom or core box bit you have.
Screw the template to your sign material and rout the sign. I usualy use 1X or 2X redwood and make the letters about 1/4" deep. You can edge glue pieces and make your signs any shape you want.
Hi Tom,
Why 1/4" MDF?
Where is the best place to buy PC template guides? Which one do you use?
What type and size bit do you use?
Your method seems to be the best advice. Thank you for your help.
Dario
First, look at your router and make sure it accepts PC temp guides. You can purchase these on line (Rockler, Woodworkers Supply) or at Home Depot, or any good tool outlet. Most routers and lam trimmers do accept these.
I use a variety of bits depending on the size of the letters. Mostly 3/8" & 1/2" core box and flat bottom bits. Just cut out the letters so the outside of the temp guide will move smoothly. Doesn't have to be perfect, just make sure it doesn't bind.
I use 1/4" MDF because it's cheap, light, and doesn't splinter like ply.
Tom
Im trying to find at least 3" tall templates and having no luck. Checked woodcraft & rockler. Any ideas?
I found mine at HD back at the signage area. You might also try an office supply store. I think HD had'em as large as 5".
Thanks, I'll give it a whirl.
I am not sure exactly what you are looking for. When I need letters that big I use my computer and printer.
What Im doing is routering a letter in the back of a handmirror.
I would suggest skipping the router and using a very sharp knife to "chip carve" the letter (much easier than it might seem, and definitely easier than the router in this case IMHO).
One step ahead of you! Went to woodcraft today and bought two pfeif knives and talked to their carving instructor and signed up for a class. Thanks.
Very cool! Good luck- their classes are pretty good (at least in my area).
Oh yeah, Ive taken one of their woodturning classes and enjoyed. Its amazing, the older I get the easier it is to admit what I dont know.
If you are doing a small number of signs--one or two, then consider hand carved letters. One good sharp chisel will get you a long ways. Also, you are not limited to some-one else's choice of letter style.
Tom
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