Building the cut files for the Pedal Power sign was easy and quick once the vector files were complete. The sign faces were only three steps. First I created a flat relief.
I then modified this relief by using the dome tool.
The letters and rivets were created as a last step – using the same dome tool (with slightly tweaked settings) once more.
The sign is to be built in five layers. The front and back (cut from 2″ thick 30 lb Precision Board. The three middle layers would be cut from 1/2″ thick Precision Board. The gears would then be cut separate which would allow all of the gears to read as separate and look more believable. The square lines are for a cutout, into which I will insert a welded step frame.