Building Curved Shapes with Precision Board HDU

Coastal Enterprises, manufacturers of Precision Board HDU, is proud to announce a series of guest blogs written by Dan Sawatzky of Imagination Corporation, which will be posted on the Precision Board Blog each month. In this month’s entry, Dan Sawatzky talks about how to get curved shapes out of Precision Board HDU PBLT-30 for their Hazelnut Inn project.

curved shapes

One of the many creative things you can do with Precision Board is build curved shapes. Precision Board is created to remain stable and true but there are a few tricks we know how to make do wonderfully whimsical shapes if the need is there. This isn’t included in the direction manual. 🙂

A current project called for us to do exactly that. We needed a curved scroll to fasten onto the back transom of a full-sized sailing ship. We knew from past experience just what to do.

I first put a straight edge across the curved hull of the ship and measured the length across, then the distance our straight edge was from the surface on both ends. We determined the curve to be just over three and a half inches high in the middle over a fifty-eight-inch length.

I then designed the scroll in EnRoute, complete with lettering. I made three layers of scroll files. The top two layers were the same save for the lettering in the top layer. The bottom layer of the scroll was slightly different as it had the ribbon tails as well. I would create the curved folds by hand later to keep things simple.

curved shapes

I spread Coastal Enterprises’ PB Fast Set adhesive between the layers and the aligned the pieces. I put a couple of screws through the center to stop things from sliding out of alignment. Then I bent the 3/4” thick layers over a 4” block (to give me a four-inch-thick center high point) and started clamping things down on the ends.

I hadn’t bothered to calculate how much the pieces would stagger at the end because of the different radius of the layered curves. There was a little misalignment on the ends, but this didn’t bother me as I was going to straighten things out when I did the carving. The important thing at this stage was to get the layers tight together. I used both screws and clamps.

Once things had dried I unclamped the formed scroll. It relaxed just a bit as I knew it would from experience. The scroll fit perfectly on the back of the ship on trial. Then it was time for a little hand sculpting with the air powered die grinder. This is quick work, even on the tough 30 lb Precision Board. I first rounded the ends and formed the looped fabric folds on the end. Then I went over the entire surface, purposely leaving a consistent but random texture, making it look hand-carved in the process.

As we developed the plans we did the concept drawing for Hazelnut Inn. The old sailing ship will protrude out of the side of the tower. To keep with the theme, we named the ship the ‘AVELLANA’ which just happens to translate from Spanish to Hazel Nut.

With the plans in hand it was first time to build the scale model. We took the time to add a lot of detail for it was a quick way to work out all the issues we would be dealing with at full size. That has proved to be a good investment as we refer to it often!

curved shapes

We are prefabricating all we can in the comfort of the shop and at ground level. We began with the hull of the ship. Making it upside down was the easiest way to do it. We would turn it over with the help of a giant crane later.

curved shapes

The ship’s cabin was the next stage. We first welded up a structural steel frame and then a sub-frame of pencil rod. Galvanized mesh was next. We then troweled on a thick coat of fibre-glass reinforced concrete which we hand carved to look like the ship’s timbers.

curved shapes

The ship’s hull was lifted into place first and welded to heavy steel embedded into the cast concrete. The heavy steel braces will be themed to look like heavy timbers which are holding up the ship. The walls will also be covered with theme work to make it look like the concept art.

curved shapes

The roof of the ship and top of the stern were built in much the same fashion. This piece is now in the final stages of the painting process. This section is where we needed a dimensional school with the name. This piece was to be built of Precision Board and needed to curve to match the shape of the stern.

These pictures illustrate the clamping process over a block in the center of the scroll. Because we used 3/4” thick Precision Board I could easily curve the pieces as needed. Once glued they retained their shape.

curved shapes

An airpower die grinder makes the shaping of the curved ends an easy task. I purposely added texture as I wanted the piece to look like I hand-carved it when I was done.

The finished scroll fit perfectly on the curved surface of the ship’s transom and it looked like it had been hand-carved, back when the ship was built. Now it was ready for paint!

Sawatzky’s Imagination Corporation is a small family company that specializes in the design and creation of dimensional signs and environments. They tackle projects of any size from small signs to entire theme parks. Their work has garnered numerous national and international awards.

Dan Sawatzky is best described as a creative force and visual storyteller extraordinaire. His art career spans almost fifty years of magic. Dan’s passion is to design and create imaginative places that take people from the normal world to a setting of delight and wonder.

Coastal Enterprises manufactures Precision Board HDU, a versatile, cost-effective and eco-friendly urethane sign material that is particularly effective for making professional-looking indoor and outdoor dimensional signs.  It is a closed-cell rigid substrate that does not rot, warp or crack.  You can request free samplesget a quote or sign up for periodic newsletters packed with helpful information.

Modern Signage to Match Historic Architecture

When Shane Durnford was asked to design and fabricate a handcrafted sign for the Peel Heritage Complex (now called The Peel Art Gallery, Museum and Archives) fifteen years ago in Brampton Ontario, he did his research.  The sign was designed within the historical time period and form of the building’s architecture, resulting in a seamless and authentic design. Shane tells us how he used Precision Board HDU, a copper roof, Wiarton stone base and bronze and gilded lettering to create a brand new sign that looked like it had always been there.

historic

When the Peel Heritage Complex owners needed some signs to compliment their historic site, they approached Shane Durnford.  They were looking for three signs in total- a directional sign on the side 12 feet tall, a long sign on the lawn about 15 feet long and then some modern touches to the sign on the building itself.

Shane says, “I’m a sign specialist, as much as a sign maker. The visual fit and placement with surrounding environment greatly influence the effectiveness of the final product.”  He adds, “I tell clients they are hiring me for my expertise as well as supplying the product.”

“I followed a design process that follows a criteria developed from research and discovery,” says Durnford.  “I designed the bases and they were contracted out.  The signs themselves were created in the studio and then assembled on location,” he adds.

historic

He sketched the designs, redrew them in Adobe Illustrator then scaled them to full size and hand-crafted them out of PBLT-18 Precision Board HDU using traditional woodworking tools including a wood lathe (for the corner pillars ), bandsaw, table saw, and carving tools. There were no CNC machines used.  Everything was done by hand.

The base is limestone from the Niagara escarpment, a native stone that was traditionally used throughout Ontario in the 1800’s.

The roof is copper that was patina’d.  Shane says copper was a natural choice for this.  He then used pot lighting to light the sign up at night.

“The principal criteria was that the signs had to look like they had always been there,” he tells us.  “We had to match the architecture, the building and historic vernacular.”

historic

“They had a reader board originally, something very modern. It was a full disconnect from the historic setting and architecture, especially considering the site was a landmark in the area and they used it for period movies,” Shane says.  “I researched the history and time period so I could get inside of the thinking behind the architectural forms and materials used. This was the framework for the sign designs.”

Shane says he loves the challenge of creating new signs that authentically blend with historic buildings and their stories. 

“I look at everything- after all the research and information is gathered, I then tuck it away and go by feeling. It tends to design itself this way.”

Durnford says for projects like this, he’ll go back to the history of the building and research the time period and architecture.

“I want to understand why they did what they did and then that gets infused into your design. It’s creating a story. How it’s going to be used. It’s a nice blending of all of it, combined with the quality of materials used.”

Shane says too many signs these days are new interpretations of old pieces and they fall short- there’s no story. The very thing that gives it soul.

“Old buildings were intuitively designed using natural proportioning and patterns, You look at old buildings and you feel and connect on a visceral level,” he says.  “You look at a new building and it’s usually void of these values, and connection.”

Shane says, “I feel signs are all about story telling and intimate communication. They can bridge a strong connection not only to the subject they represent but to ourselves as well. A making for a very effective branding and marketing tool.”

It took Durnford about two to three months to make all the pieces, including the structure it was on and getting all the copper applied. To assemble it took a couple of days.

When the Peel Heritage Complex was renamed to The Peel Art Gallery, Museum and Archives, Shane was asked to come back and retrofit the signs in 2012.  You can see what they look like right now in the photos below.

Shane graduated from Toronto’s George Brown sign-writing program in 1981. With lettering quill in hand and a box of paint, he started from a humble shop in Creemore, Ontario and, within a few short years, had become a highly sought-after Sign crafter. As a Registered Graphic Designer, Shane quickly became known for not only his superb hand crafting skills but also for his novel image consulting and design services, across various mediums: logos, websites, promotional/advertising material, illustration, corporate branding, and showpiece signage. His unique brand is sensory storytelling thru maximum impact, multifaceted visual imagery.

Shane’s work and articles have appeared in international trade publications. National exposure in major Canadian magazines and television. His work, as well as articles, are well respected within the industry. He has hosted design workshops, participants from as far away as Australia. He is retained as key note speaker for branding strategies by municipalities.  Shane Durnford Studios can be found on a variety of platforms, including his new Instagram account.  For more information and other social platforms, check out his website.  Design & Carving workshops are being organized for Summer 2018, more information to come. Email Shane to receive more info and pricing when it becomes available.

Coastal Enterprises offers free samples of Precision Board HDU.  You can also sign up for our monthly blog roundup, which is jam-packed with helpful blogs on people like Shane doing creative and interesting things with Precision Board.  You can also give us a call with your questions at 800-845-0745.  We’d love to hear from you!

Creating New Signage to Match Old Architecture

When Shane Durnford was asked to design & fabricate signs for the Peel Heritage Complex fifteen years ago, he had to make them look like they had always been there. To accomplish that, he had to do his research and use materials and design techniques that matched the aesthetics of the historic buildings. The signs were designed within the historical time period and form of the building’s architecture, resulting in a seamless & authentic look. Shane tells us how he used Precision Board HDU, a copper roof, Wiarton stone base and bronze & gilded lettering to handcraft new “old” signs.

The building owners were looking for three signs in total- a directional sign on the side 12 feet tall, a long sign on the lawn about 15 feet long and then some modern touches to the sign on the building itself.  

“The principal criteria was that the signs had to look like they had always been there,” Shane tells us.  “We had to match the architecture, the building and historic vernacular.”

He adds, “I’m a sign specialist, as much as a sign maker. The visual fit and placement with surrounding environment greatly influence the effectiveness of the final product.” 

“I tell clients they are hiring me for my expertise as well as supplying the product.”

“They had a reader board originally, something very modern. It was a full disconnect from the historic setting and architecture, especially considering the site was a landmark in the area and they used it for period movies,” Shane says.  “I researched the history and time period so I could get inside of the thinking behind the architectural forms and materials used. This was the framework for the sign designs.”

Shane says he loves the challenge of creating new signs that authentically blend with historic buildings and their stories. 

“I look at everything- after all the research and information is gathered, I then tuck it away and go by feeling. It tends to design itself this way.”

“I followed a design process that follows a criteria developed from research and discovery,” says Durnford.  “I designed the bases and they were contracted out.  The signs themselves were created in the studio and then assembled on location,” he adds.

He sketched the designs, redrew them in Adobe Illustrator then scaled them to full size and hand-crafted them out of PBLT-18 Precision Board HDU using traditional woodworking tools including a wood lathe (for the corner pillars ), bandsaw, table saw, and carving tools. There were no CNC machines used.  Everything was done by hand.

Shane says too many signs these days are new interpretations of old pieces and they fall short- there’s no story.  Something he says is the very thing that gives it soul.

“Old buildings were intuitively designed using natural proportioning and patterns, You look at old buildings and you feel and connect on a visceral level,” he says.  “You look at a new building and it’s usually void of these values, and connection.”

It took Durnford about two to three months to make all the pieces, including the structure it was on and getting all the copper on. To assemble it took a couple of days.

The base is limestone from the Niagara escarpment, a native stone that was traditionally used throughout Ontario in the 1800’s.

The roof is copper that was patina’d.  Shane says copper was a natural choice for this.  He then used pot lighting to light the sign up at night.

When the Peel Heritage Complex was renamed to The Peel Art Gallery, Museum and Archives, Shane was asked to come back and retrofit the signs in 2012.  You can see what they look like right now in the photos below.

Shane graduated from Toronto’s George Brown sign-writing program in 1981. With lettering quill in hand and a box of paint, he started from a humble shop in Creemore, Ontario and, within a few short years, had become a highly sought-after Sign crafter. As a Registered Graphic Designer, Shane quickly became known for not only his superb hand crafting skills but also for his novel image consulting and design services, across various mediums: logos, websites, promotional/advertising material, illustration, corporate branding, and showpiece signage. His unique brand is sensory storytelling thru maximum impact, multifaceted visual imagery.

Shane’s work and articles have appeared in international trade publications. National exposure in major Canadian magazines and television. His work, as well as articles, are well respected within the industry. He has hosted design workshops, participants from as far away as Australia. He is retained as key note speaker for branding strategies by municipalities.  Shane Durnford Studios can be found on a variety of platforms, including his new Instagram account.  For more information and other social platforms, check out his website.  Design & Carving workshops are being organized for Summer 2018, more information to come. Email Shane to receive more info and pricing when it becomes available.

Coastal Enterprises offers free samples of Precision Board HDU.  You can also sign up for our monthly blog roundup, which is jam-packed with helpful blogs on people like Shane doing creative and interesting things with Precision Board.  You can also give us a call with your questions at 800-845-0745.  We’d love to hear from you!