Bailey’s Project: Day 4

It’s day four and we are making great progress – the sign is REALLY taking shape.  All the precision board cuts are done and the letters are all completed as well. Brian is hard at work fabricating standoffs, welding, sculpting and assembly. Once the sign is put together and the parts sculpted just right he’ll take it all apart to begin priming.

We cut the “smokehouse” letters out of 1/2″ black PVC.  And the larger 3D Cut “Bailey’s” out of 1″ thick 15# Precision Board HDU.

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Published with permission from KDF Custom Graphics. Source.

Bailey’s Project: Day 2

Day two is underway!

We’ve made some great progress in all areas. Brian’s been hard at work welding up the grill.  It looks incredible and will really make this sign feel authentic.IMG_3266

I’ve been programming the face and ribbons and working out the depth of the overall sign. In Enroute I’ve programmed the basic shape of the ribbon with the text – once I’ve cut it out of Precision Board HDU Brian will do some hand sculpting to remove the “machine cut” look.

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Published with permission from KDF Custom Graphics. Source.

Disney’s Frozen Project – Times Square Disney Store

Who wouldn’t love working on a Disney project?  This was a fun project with characters, castles and great Disney graphics. We just completed our work, delivered to our client they added their magic and it looks fantastic! If you are  in Times Square NYC this holiday season check it out.

We started out by vectorizing the clients sketch of a giant snow arch and castle with the “Frozen” logo carved into it. In Enroute Pro we gave the outline shape and texture and designed the accurate dimensions to fit on the store fixtures.293294Now this arch is about 16′ Wide so we cant cut it all at once.  I’ll break up the file and start cutting the pieces.

So to keep the weight down we chose to make the arch out of blue insulation foam.  We started by gluing 4′x8′ sheets of 2″ foam together.  Our arch will end up 8″ thick. Once glued we are ready to cut.

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Once the panels are cut – we cut out a channel on the back to set the PVC piping wich will hold the pieces together. The PVC is set in place and the safety cables are installed and crimped.

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The adhesive is applied and the sides are assembled.

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Now we’re ready to tackle the bases! These need to be large solid pieces of foam so we cut them in discs that will sit on top of each other then Brian will come in with a sawzall to rough sculpt it. Here you can see Eddie assembling the discs and gluing in place.

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We’ll finish up the other base and start sculpting. Brian got out the sawzall for the rough cuts then the belt sander for the second go around.

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Mark and Kevin doing some finishing sanding.

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Here’s Brian and Greg with their homemade sanding tool – Great for taking away a lot of foam fast.

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Ready for Bondo and Paint!

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While the arch is off to the paint shop we’re busy printing away and building some other cool features for the install.

Here is an 8′ Marquee Gift Tag.

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A GIANT painters pallete.

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Lots of wrapping paper….

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Some cool Mickey Ears….

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and a bunch of other cool stuff.

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And here is the transformation (with the help of our clients amazing design and installation skills)

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AFTER:

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Published with permission from KDF Custom Graphics. Source.

Completing the Structure – Mechanical Fish Project

All the welding is done. The leveling feet are on and the steel structure is now complete and painted. All I have to do is cut the acrylic tray for the top tank and we are done with stage 1!

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For the base of the top tank we used 2″ acrylic – overkill maybe – really cool custom acrylic fish tank tray – definitely!

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I designed the cut in Enroute Pro then sent it down to the Multicam to do all the work.  We screwed some MDF to the table to keep this block in place. 1/2 an hour later – a perfect cut came off the table!

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A quick leveling and we are looking good. Onto the next stage!

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Published with permission from precisionboard.blogspot.com. Source.

The Mechanical Fish Sign Competition Project – Base

“After Hours” has a new meaning here at KDF.  It’s when we get to have fun and really get creative.  It is amazing how much work you can get done when the phone isn’t ringing! Our mechanical fish project is moving along nicely. We’ve just completed the panels for the base which will sit atop a slab of stone. We started by routing the panels from 1.5″ 30# Precision Board on the Multicam 3000.

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The Mechanical Fish Sign Competition Project – Base