The Lark Rise sign was next up on the agenda. I created the lettering vectors in Illustrator and then imported them to EnRoute where I created the rest of the vectors for the design.

The sign face was fairly simple, with the inside to be routed out. The flags along the top were raised and bevelled.

I put some wood grain in the background using a sandblasted redwood bitmap from my TEXTURE MAGIC collection. 

The lettering outline was built as a separate flat relief, moved into position vertically and then merged highest with the background.

The lettering was prismatic lettering created with the bevel tool and a 0.15 base.

The triangle on the bottom of the sign was also rested with the bevel tool as a separate relief before being merged highest with the background.

The sign will be cut in three layers, the top face being routed from 1.5″ thick 30 lb Precison Board. The middle and back layers will be cut from 1″ 30lb Precision Board. I will weld up a steel frame to glue into the center to provide strength. Since I’m using 1″x1″ square tubing I created  1.1″ cuts through the center piece to make room for the steel. The glue will fill in any gaps.

The two cutting files for the middle and back looked like this when I was done. These will be shaped using an offset cut.

Stay tuned as the sign comes together…

-dan

I love curves, textures and fancy bits, especially if they take a good design over the top. The fourth axis opens up a whole world f possibilities that weren’t easy previously. It is pretty exciting.

In the last post I showed how we built a file of the twisted and fluted post with a beautiful taper. Now it was time to let the machine do the work. As I build more files and experiment with the tool pathing I am slowly getting more familiar and comfortable with it. I learn best by repetition and experimentation – both of which take time.

Here’s a short movie of the process…

This whole fourth axis routing thing is forcing me to think in brand new ways. Being all new means I really have to work at getting it right. I’m sure that over time it will become familiar and quicker. Knowing EnRoute means I don’t have to learn much as far as the program itself. But this was using EnRoute in a whole new way. 

The first thing I had to determine was how I would glue up the blocks with the maximum usage of my material. 

I decided to cut the blocks to shape in the top view as well. While it wouldn’t save much materials it would save a bunch of sawdust on the floor as I routed and perhaps a little wear and tear on the machine. I would cut a rounded center slot in the two center pieces to accommodate the steel pipe I would glue in there and use as a centerpiece to clamp to. This steel would also provide structure to the sign post. The center slot was created as an inset relief. The balance of the routing would be simple offset cuts. The MultiCam made quick work of this project. Each piece would be cut twice.

Once the MultiCam was done it was time to start gluing up the 30 lb Precision Board. I used Coastal Enterprises PB240 – a one part glue activated by a spritz of water. It expands as it cures so lots of secure clamps are necessary.

 

We are almost ready to kick the lathe into gear. Stay tuned…

-dan

The center section of the post is the next assignment. It will be routed on the four axis MultiCam. First I had to determine the scale and shape of the piece. I called up the tracing I had done of my concept drawing. I duplicated the center section flipped it and lined it up before merging it with the first half. I then measured the diameter, length and also did a trace of the profile. These measurements and the vector would be used later.

I wanted the post to look like it was turned with flutes winding around. to create these I drew a long rectangle and then used the duplicate menu to create a 12 copies.

I created a rectangle that was 36″ tall by Radius times Pi. I positioned the pieces, rotated the flute vectors so the joining sides would line up. I created two horizontal vectors to line up with the ends, and also lined up the profile. 

I selected everything and rotated it so I would create the relief in the horizontal position. First I would create a mesh file of the profile using the sweep two rails function. It is a simple process. I selected the mesh command., then defined the slices and stacks. I tend to use higher numbers than necessary but my computer can handle the large files. The command prompts make it easy. Select first rail, then the second.

Then it asks for the swap sections. Clicking twice on the profile will define the shape all the way across with the same profile.

The mesh looks like this when it’s done. 

I then created a zero height relief (in yellow). When I hit the render button it only showed part of it. This immediately told me the mesh profile was too low.

I checked the front view and sure enough the mesh file needed to be raised.

The next operation was to merge the mesh with the relief, I selected both the mesh and the relief which lit the combine button. I used the ad to button and hit apply. 

In an instant we had a relief in the shape of the profile of the post. 

Next up we would create the rib reliefs. I selected the vectors and then used the dome command.

It looked like this when it was done.

I merged the profile relief (as the base relief) with the dome ribs using the add to command.

Once I was done I rendered it to check and see what had happened. It looked perfect.

In the 3/4 view I could really see what was happening.

I used the sweep two rails function to create the bottom of the column. as a quarter round. I moved it up into 

I did the same for the top of the column.

As easy as that the relief was ready to wrap for the four axis router.

The simulation of the wrapped relief looks like this…

I have to check everything over and confirm all measurements, then I’ll tool path the file and get it ready to send off to the router. Before I can do that I have to route the blocks to shape that I will be glued up for the block. It will have structural steel laminated through the center. I’ll be showing that process next. Stay tuned…

-dan

In spite of a whole bunch of other necessary work going on in the shop I could’t resist sneaking another half hour with the die grinder on the piece. I whipped on the wood grain, and as I progressed I was more than a little unsure that I may just have wrecked the piece. But I trusted my instincts and pressed on. Then I changed bits to a fine pointed one and started in on the splits in the ‘wood’ It instantly looked great – just as I had imagined.

You have to look at this piece in context of the rest of the post and sign. I want the woodgrain and weathering to read clearly at a distance. People will be looking at this sign as they drive by in a car.  As we layer on the paint and subtle glazes it will hopefully be magic. 

Now I m ready to fill in the holes and add a few details with the Abracadabra Sculpting epoxy. It’s time to kick the router into gear on the next pieces.

-dan