25 dimensional signs in a hurry!

The MultiCam has been kept running plenty of hours as the fronts and backs (and middles too) of the hole markers and rules signs have been cut.  The files were very large with all of the woodgrain detail and were cut overnight while I slept.

While the rule signs were being cut I laminated the hole markers. Each had a piece of 3/4″ plywood laminated into the center to ad strength and also provide a secure attachment for the screws.
The next task is to laminate the fronts and backs of the rule signs. They too will have 3/4″ plywood glued into the center. 

The next task is to use the die grinder to add woodgrain detail to the edges. Even with 30 lb Precision Board this job goes quickly. And then it is off to paint. Stay tuned for that process.
-dan

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

Hole number markers

May has been one of my most frantic months I can remember in some years. At long last I seem to be getting my feet under me once more. After a week of having no time to build files I have at last got back to my desk once more.

The WhistlePunk Adventure Golf signs are the next thing to be done. It is not often we do batch work where multiples of similar signs need doing but a project like the golf needs just that. EnRoute and our MultiCam are good at that sort of thing. With a reliable machine I set the machine in motion and then only check it once in a while to make sure things are going as they should. Best of all the files are large which means once I made the files the router will churn away for many hours. I’ll then throw on another sheet of Precision Board and hit the go button one more time.

The hole markers were today’s first task. The signs I am routing today are the fronts and backs. The middle layer which has a hole in the center for the plywood for mounting.

The signs are woodgrain with raised lettering.

As always it started with the vectors. I used my own font called ‘quickdraw’. For those interested it is available at letterheadfonts.com

I created three different wood backgrounds. I then duplicated, rotated and flipped these backgrounds until I had 17 different plates to start with. I then duplicated and flipped them one more time to create the backs of the signs. I then spaced them out on my board and centered the numbers on the reliefs.

 

 I created the number outlines as flat reliefs. These reliefs were then positioned vertically to clear the woodgrain backgrounds.

The number outlines were then merged highest with the base relief. This had to be done one relief at a time as it can’t yet be batched in EnRoute.

Lastly the numbers were added to the reliefs using the dome tool They have an upright edge (base) of 0.15″.

Then it was time to send the file to the MultiCam to be routed from 30 lb Precision Board. The file will be routed using two passes. The rough pass was with a 3/8″ ball nose bit at a 50% overlap. The final pass was using a 1/8″ ball nose bit with an 80% overlap. Here’s a pic of the rough pass in progress.

Tomorrow I’ll be gluing all these signs up and setting the next batch in progress. Stay tuned…
-dan

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

Logging truck sign

The Shay Steam train at WhistlePunk Hollow has a companion piece as well. For the seventh hole feature we sculpted a logging truck. Like the log car on the locomotive we fashioned the sign face on our MultiCam with 30 lb Precision Board. The file was created in EnRoute in the very same way as the logging railroad car. This time the wording was a little simpler (no adventure golf) as it is a secondary sign. The balance of the truck was created from welded steel and fiberglass reinforced concrete.

The golf green will go under the giant log and the ruck will also function as a photo opportunity. Who could resist climbing into the cab for a picture?

I’ll be delivering this piece on the weekend. The shop parking lot is full of other pieces almost done as well. We still have a lot of routing to do for the project with another 29 secondary signs to come. Stay tuned…
-dan

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

Train on the trestle

Yesterday was an exciting day as it was time for the second delivery to the WhistlePunk Hollow project. Each time we make a delivery it is a fun drive with lots of waves, wows and thumbs-up along the way.
The log car was the first piece to be lifted onto the trestle which the client had built. It went up smoothly and without a hitch.
The engine was a little trickier to slide into place. Jeff, running the big excavator confidently and skillfully nudged it into position without a scratch. Our job on the trestle was to simply guide it into place between the marks.

The train looked spectacular in place, perfectly in scale with the trestle. It reads perfectly as you approach the golf from the town. 

It was smiles all around as I drove away.
-dan

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

Building a train – part 16

I posted pictures and a small writeup of the log car that would accompany the steam locomotive on the Whistle Punk Hollow Adventure Golf project. That article covered creating and routing the face of the log which would act as a giant sign. Around that we welded up a framework of quarter inch thick steel bar, then attached expanded lath to that framework. Over this we troweled on a thick coat of fibreglass reinforced concrete and then as it dried carved in the woodgrain and bark textures. This was allowed to cure for a few days.

We then primed the Precision Board face of the sign with FSC-88 WB primer. This too was allowed to cure before we began painting the log with two base coats of acrylic paint. 
We then applied a couple of coats of darker brown glazes. wiping off the excess and leaving the crevices dark.
The lettering was painted and then all of the undercarriage assembled. Today was the time at last to drag the piece from the shop and load it onto the trailer in readiness to transport to the site.

We transported the locomotive last week. As always the journey was fun!

Stay tuned for more instalments…
-dan

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