Sawatzky Guest Blog: A Hazelnut Inn Update

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. This month Dan Sawatzky gives us an update on his passion project – The Hazelnut Inn, and points out all the different places that PBLT-30 Precision Board HDU is used to make this themed bed & breakfast look so fantastical!

In Dan’s own words…

Many of our projects are very large and it is not unusual for them to be in our shop for a year or more before they are installed and complete. The Hazelnut Inn is a personal project and has to fit around our customer’s projects. It is also very large and the most detailed we have ever taken, so it will take a long time to complete. We’ve been at it four years so far and it will be at least another year before the first suite is open to guests. But we are making great progress and it is looking spectacular!

While much of the project is fabricated using hand sculpted fibreglass reinforced concrete, we are also using a lot of Precision Board HDU where it is applicable.

From the road things are looking pretty colourful. The building certainly catches everyone’s eye as they drive by!

We used precision Board on many of the details including the roof caps, finales and the primary sign in this picture.

The stature of our heroine is also sculpted from 30 lb Precision Board.

hazelnut inn

The North Star suite is the most complete thus far. It is the unit closest and most visible from the road. We are currently doing the sculpting of the lower section where guests will enter the garden. The North Star sign was fabricated almost four years ago (one of the first projects while we were waiting for our building permit).  We finally installed it on the rudder of the ship in the last couple of weeks.

Adjacent to the North Star entry is the maintenance room for the Inn. This area is where the cleaning supplies, storage and laundry will be for the staff. It is probably the fanciest entry to a staff area in the whole world!

The faux shutters are fabricated from PBLT-30 Precision Board HDU to match the adjacent wood doors.

hazelnut inn

Adjacent to the service area is the Under Hill suite. We are now beginning the theme work on this area. It will have a private 600 square foot garden in front of the unit. The hand crafted gate is soon to be installed.

Today we did the faux brick work around the pocket in the wall which allowed us to install the Under Hill sign at last!

hazelnut inn

While we were at it we installed the Copper Crown sign on the castle suite. It won’t be until later this summer that we do the theme work on this portion of the building.

Inside the building, the North star suite is further along. Inside the ship the sleeping area is almost complete. The headboard, figureheads and clamshell light fixtures are all 30 lb Precision Board.

hazelnut inn

There are many other prefabricated pieces already finished, tucked away for safekeeping for now. As we get into more finishing we will be using more 30 lb Precision Board for fabrication as it is easy to work and holds detail extremely well.

I’ll provide another update on The Hazelnut Inn as we get a little further along. Stay tuned…

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.

Sawatzky Guest Blog: A New Tool to Cut 3″ Thick Precision Board

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. This month Dan Sawatzky talks about working with X-Edge Tools, a router bit manufacturer, to develop a bit that would cut through 3″ thick Precision Board.  Dan lays out his process step-by-step of working with Jay at X-Edge to get just the right router bit for the job!

In Dan’s own words…

In our shop we are always on the hunt for new materials, tools and methods to do our work better and more efficiently. While we discover a few things on our own, most often others in the business are our teachers. Even after more than fifty years in the sign business I find there is so much new to learn! You can teach an old dog new tricks it seems.  🙂

I was talking to our good friend Jay at X-EDGE Tools a while back about a few challenges we were having as we fabricated our signs using Precision Board. Because we use primarily PBLT-30 Precision Board of thicker dimensions than most, we run into difficulties from time to time. There are always workarounds that can get us by, but with the help of others we can often figure out a better way of doing things.

Jay is a master at all things to do with CNC routers and especially routing bits. He also loves a challenge. I mentioned to him that we had been using a 3/8” cutter with a 1.5” cutting edge to cut our 2” thick Precision Board HDU. By chucking it up in the collet a bit shallow (not enough bit in the collet) I could squeeze enough depth out of the bit to go through 2” of material without rubbing the collet. It wasn’t an ideal solution but it got us by for many years.

Jay asked me what I needed. I asked for a 4” long 3/8” bit with a 2.5” cutting edge. Jay had a prototype made and sent me out a 4” long 3/8” RAZOR end mill to try. I designed a file and gave it a spin. While it did the job I wasn’t satisfied. The bit was extremely noisy – a definite sign we were getting too much vibration. I let Jay know and he immediately went back to the drawing board.

A short time later I was delighted to receive a package in the mail with two 4” long – 1/2” Razor end mills. One had a tighter helix than the other. Jay asked me to put them through their paces and let him know my thoughts.

precision board

I designed a file that had straight, curved and angle cuts.  It measured about 8” x 16” by 2” thick. Then I threw some 2” thick 30lb Precision Board HDU on the router and fired it up.

Generally we do our cutting of 30lb Precision Board in 1/2” increments but since I was doing a test I ran double that with 1” deep cuts. I started at 300 inches per minute at 14,000 rpm (our normal cutting speed) for PBLT-30 Precision Board.  The first bit was noisier than I liked which I knew would translate into some roughness. I fiddled with the speeds and feeds through the cut but the results didn’t remarkably improve from my initial settings. On inspection after the cut was finished, the bit did its job and the cut quality was adequate. With a cleanup pass I’m sure it would have been fine. But since we have neighbours close by I wasn’t happy with the noise.

precision board

The second bit performed much better. The noise was much less and the cut quality was much improved as well. And I am sure a cleanup pass would make things perfect.

The reality is that in fifteen years of routing I’ve never done a cleanup pass on our work. There was no need, as we always add texture by hand to the edges of our work after we do our assembly.

precision board

I of course shared my findings (with pictures) with Jay at X-EDGE Tools. He suggested I try the bit at a higher speed (18,000 RPM) which I immediately did. To my surprise, although it ran quieter,  the bit left more tool marks at this higher speed.

So we now have a great solution to a long standing challenge. We can safely cut material that is up to 3” thick with the new bit from X-EDGE Tools. To keep the noise down I would do it in half inch passes in the 30lb Precision Board HDU. If I needed a super clean edge I would do a cleanup pass.

We will keep experimenting with various speeds and feeds to see what is optimal on our machine.

Thanks to Jay at X-EDGE Tools!  If you have a particular challenge in your CNC cutting I’d bet Jay already has (or will invent) a solution that will fill your needs. I recommend them most highly!
precision board

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.

Sawatzky Guest Blog: A Precision Board Sample for the Ages

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. This month Dan Sawatzky talks about a sample sign he made from 30lb Precision Board nearly ten years ago that has endured road trips to trade shows and lived in different spots in his studio/showroom.  It just goes to show the staying power of signs made from Precision Board high-density urethane (and the limited upkeep on them too!).

precision board

In Dan’s own words…

We built this sign back in the fall of 2010 – almost ten long years ago! It was a sample piece I created during our slow time in the financial recession. The sign was honoured with national and international awards and was featured in the trade magazines too. Best of all this sample sign brought us tens of thousands of dollars of paying work.

It weathered a lot of miles in the first couple of years. It travelled to a number of trade shows. It lived in my design studio when it wasn’t on the road. About five years ago we cut off the heavy duty floor stand and instead fashioned a new wall mount. It’s been moved from time to time when we rearrange the shop but it has lived on the upper wall of our workshop since then. Two or three times each year when we do a deep clean this sign gets the dust blown off along with the other 150 samples that live there.

precision board

The sign is made using PBLT-30 Precision Board HDU and still looks as good as the day it was finished.

Ed note: You can read all about how Dan put this project together back in 2011 with our throwback blog HERE.  He ended up winning first place in Sign Media Canada’s Stand Alone Sign category for this sign.  Here’s a photo from when he created it almost ten years ago.  Hard to tell the difference between then and now!

precision board

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.

Sawatzky Guest Blog: No Time Like the Present to Plan for Your Future

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. This month Dan Sawatzky talks about using the current COVID-19 down time to work on samples for your showroom or to spend time on your own shop sign, all with future sales and business in mind.

samples

In Dan’s own words…

We are all in an unprecedented situation without a doubt due to the COVID-19 pandemic. Many sign makers are sitting at home waiting this out. Others are still able to go to work but projects and business has undoubtedly dried up in the last weeks for most shops. It is a distressing situation and far beyond our own control.

In our home-based business we are able to keep going for now. We have a large project that will keep us busy for a few more weeks yet but future projects are all suddenly on hold. We simply do not know when things will resume once more.

I’m not one that can simply sit idle and wait it out. While I understand the situation is unbelievably serious I still find myself looking towards the future. This is a wonderful opportunity to do some of those things we’ve long been putting off.

I’m asking myself, as I did during the great recession, what do I want to be doing when the good times return? We know they always do. It is time to get ready. When business resumes you will need to have some great samples to show your customers if what you wish to do is out of the ordinary.

For me that means it is time to make some samples for our studio walls. They don’t have to be large but each one should push the boundaries of what you are capable of. This is the chance to use up all those scraps of Precision Board HDU we’ve been hoarding. It’s a great time to learn that new software to do it. And it’s time to brush up on some new sculpting and painting skills.

During the last financial crisis I made the commitment (to myself) to make one outstanding sample per month. If things slow down or even stop for a while you should be able to do more than that.

Those samples I invested in the last time brought us many hundreds of thousands of dollars of work since then and still serve us well to this day.

Start small and with each project push a little further than ever before. I have made many name plaques for family and friends. Next Christmas when money may well be a little tight they will make great presents. These name plaques are a great way to experiment and learn new textures and finishing techniques.

I had time to make some more elaborate projects as well with time on my hands. I designed and made samples of the kinds of signs I wanted to make in the future.

samples

samples

I used that time to create a showroom full of samples that would make my clients gasp when they entered. There are more than a hundred and fifty hanging on our walls. These samples helped sell this kind of work in the ten years since they were created.

One of those many small sample projects was this model of the OGOPOGO (A fabled lake monster that resides in Okanagan Lake)

Last year a client saw the model I had done eleven years ago and ordered a full sized version. Last week we delivered it to our customer. Sample work!!!!

As we think about projects to give us the best opportunities in the future we absolutely should not forget about our own signs. What image do you want to present to your future customers? Your own sign should reflect the very best work you can possibly do. We made this sign during the last slowdown. It has won numerous awards, been featured in various magazines and most importantly brought us a ton of wonderful work. You will never have a better opportunity to create a showstopper for yourself!

We extended our creative efforts to all sorts of ‘home’ projects. They raised the bar for our future paying projects.

If you are stuck for ideas or how to proceed I would recommend browsing through the blog I created for Precision Board that features many of these projects (Ed note: that blog is no longer updated, but Dan continues to write monthly guest blogs like this one for the main blog). There are plenty of step-by-steps to help you along.

You have time NOW!

Stay well and be safe. Use your quiet time to get a head start on the good times in the future!

samples

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.

Sawatzky Guest Blog: A Love Letter to 30lb 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. This month Dan Sawatzky goes into great detail on why he prefers to use PBLT-30 Precision Board HDU almost exclusively over lighter densities like 15lb and 20lb.  He also talks about using a range of Precision Board densities depending on the specific project, from PBLT-4 all the way up to PBLT-60.

In Dan’s own words…

We love Coastal Enterprises Precision Board! We use TONS of it each year (literally).

Precision Board HDU is manufactured in a wide range of densities. It is measured in pounds per cubic foot. We have used everything from 4lb (PBLT-4) board to 60lb (PBLT-60) board in our shop (Ed note: the highest density of Precision Board is PBLT-75 and the lowest is PBLT-4). Which density we use depends on what we are creating. For quick sculptures (typically study models) which will be covered in sculpting epoxy we love the 4lb. It is so soft we can carve it quickly with a variety of hand tools. We typically keep a sheet or two of four inch thick stock on hand. We have used various weights of board through the years but generally stick with 30lb (PBLT-30) Precision Board. If we have a project (such as a door panel) that is in a high traffic area we will use 40lb (PBLT-40) or even 60lb board. We keep a couple of sheets on hand for projects like this.

The ’standard’ in the sign industry is 15lb (PBLT-15) or 18lb (PBLT-18) board and occasionally 20lb (PBLT-20) board.

precision board

While most sign people I know tend to go for the lighter densities (15-20lb Precision Board) we favour 30lb board almost exclusively.

It makes perfect sense to us and the reasons are many.

The 30lb board holds detail superbly and is much tougher than lighter weights. It can be machined at the same quick speeds (typically at 300 inches per minute) with our MultiCam CNC router.

Imagine you work on a sign for many hours. During this process you transfer the almost complete piece to a different work table. There’s a screw laying there which you don’t see. If you are using 20lb board or less you will soon have to make a repair. How much did you save by buying lighter board? If you count your time properly you most likely just lost more money than you might have saved by using lessor boards. The 30lb Precision Board can easily survive those types of bumps and bruises without a scratch. Some people I know use a lighter board and then apply a hard coat to protect it. That makes no sense to me for you lose hard earned detail in the process plus you incur extra material and labour costs as well.

The heavier weight material is easy to sell too. We keep a variety of labeled samples on hand for just this purpose.

When I am explaining to a new customer the quality materials we use in our shop I grab a 15lb or 18lb sample piece and easily run my fingernail into the surface. It leaves a nasty scar. The customer is always shocked. I explain that this is what our competition typically uses. Then I hand a 30 lb sample to my customer and ask them to do the same. It doesn’t leave a mark. I ask the customer if they are willing to pay an extra $50 or $100 for that kind of quality. The answer is always YES! As easy as that I’ve sold them on a premium material and made some extra cash in the process.

precision board

We generally keep three thicknesses on hand; 1”, 1.5” and 2”.  We have some other thickness left over from previous projects which includes some .5”, 3/4”, and 1.25” which we draw from as needed. It is less expensive to order extra and stock it than to make a panic order and pay a premium for the rush.

Because of space considerations (lack of storage) and ease of handling we keep only one density in stock. We buy once or twice each year – in bulk. For a single sheet our shipping costs can equal the price of the material. When we buy a pallet or two the freight is generally less than three times the price of shipping a single sheet. The savings add up in a BIG hurry! Plus I’ll bet your dealer will happily negotiate a better price when you purchase a large order. And if we order a year’s supply of glues and primer at the same time- those boxes ride for free on top of the pallet for further savings.

We are about half way through our most recent order of Precision Board. We keep it under a roof out in the storage area. Another twenty sheets is kept in the router room for handy access.

precision board

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.