Custom Carved Town Sign – Borough of Rockleigh, NJ

Our office is located in a tiny borough tucked away in the Northeast corner of NJ.  Its a beautiful little area of NJ – We were honored to be chosen to redesign and create the new signs for this this historic district of Rockleigh.

After a few concept drawings we came up with the final design which was in line with the existing borough signage and had the elegant historic feel they were looking for.


Once approved we sat down and came up with a unique way to construct the sign.  Our goal was to build a dimensional sign that would last but also have elements that are not used in typical town signage.

As always we’ll be making the sign from 30lb Precision Board – This is our favorite material and will last forever!

We start by cutting the signs face up and routing pockets to place our dimensional letters later. This will make for a very interesting sign. Once we’ve cut the face we flip the sign and route out a channel on the back for the steel frame that will hold the sign up.  These signs are double sided so when they are completed we’ll screw and glue the panels together.


To give the panel some interesting depth we re register the panels on the MultiCAM 3000 and route steps on the edge then add a V-Bit groove for the Gold Paint.


We now have our completed panel – ready for the steel frame and letters.


We’ve cut the large letters from 1″ 30lb Precision Board HDU and chose to use 1/2″ PVC for the smaller letters.


The panels and letters are cut – everything is off to the paint shop. Brian will get started with assembly, priming and painting and I’ll work on the “roof” and ribbon for the sign.





Now Brian will start the detail work on the sign by painting the Gold V-bit channel, the letters and black edges of the sign panels – Its really coming together.




IMG_3103 The Panels get a gloss coat before final assembly.


this little detail adds a lot. Its a v-bit carved ribbon – What a paint job!


All the elements are glued in place and the roof is screwed on.  The signs are ready to go.

IMG_3127 Brian gets to hang the signs on the coldest day of the year. Luckily In anticipation for the cold weather we swapped out the old rotted sign post about one month ago. So the install is pretty simple – all the hardware is in place.

And here it is. Great job to all the guys in the shop – we are very proud of these signs.  If you ever come visit us here in Rockleigh be sure to take a look.


Published with permission from KDF Custom Graphics. Source.