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Here's a picture of the first of two identical signs I am carving right now. The sign board blanks are 59" tall X 39" wide X 1-3/4" thick Western Red Cedar. The boards will finish 57" tall X 36" wide. My shop has NEVER smelled this good! LOL I will carve one cut-out box around the address, the artwork and his name.....same as the other two boxes. The boxed areas will be painted black and the face of the letters will be painted white so they are easier to read from the road. I will clear coat the boards with a water based urethane.....new on the market.

I called this project "Big X2" because these are the biggest signs I have carved to date.....and there are 2 of them to be carved. I'm kinda ingenious that way. LOL

Sorry, I don't know what the problem is with the orientation of the picture......on my PC and my phone it is vertical, not horizontal.


On the upside of things, I am retiring from my day job in December and looking forward to getting a lot busier in my shop.......working for myself and my customers.


Thanks for tolerating an old man and his passion.
 

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Theo
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That's a lot cooler than the sign my dentist has. Think I'll save the picture, and send it to him.
 
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The first sign's carving is nearly finished. I just need to finish the detailed clean out. After the second sign is done I will cut them to the finish size.

Again, I am sorry the picture is posting in landscape. Not sure what I am doing wrong.
 

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Consider painting the words with a lighter color.

The first sign's carving is nearly finished. I just need to finish the detailed clean out. After the second sign is done I will cut them to the finish size.

Again, I am sorry the picture is posting in landscape. Not sure what I am doing wrong.
Hi Frank,
I am very impressed with your carving. However may I suggest that you consider painting the words with another color for better contrast and visibility of the 2nd sign.
The purpose of a sign is for people to be able to read the words, but since some of the wood in the background are rather dark, at a distance the words may not be read very clearly. Also, after some years, the wood would turn even darker and never lighter.
 
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Rick
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Great job Frank . Very impressive looking signs ,and look like a lot of work.The gaps in the D , are those supposed to represent cavities?
 

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Discussion Starter · #6 ·
Thanks for the questions and suggestions.

The cut outs will be painted black and the face of the letters and artwork will be painted white. The rest of the boards will only have clear coating applied. Helmsman has come out with an exterior water based finish that will not yellow the white paint......or so they say. I'm gonna give this a try and see how it works.

The sign's existing framework is in great shape......each sign's frame has two columns of bricks with 2 each 2X4 cross members extending from column to column. Each exiting sign has the mounting screws run through the face of the sign into the 2X4's.....this is NOT the way I plan to mount the signs!!!!

My plan is to bolt the signs to the 2X4's from behind......nothing going through the front of the signs. I will install brass threaded inserts with epoxy into the back of the signs, then run bolts through the 2X4's and into the back of the signs.......5 bolts per 2X4 board.....each 1" deep into the sign backs......for a total of 10 bolts holding each sign in place. Then, when the signs need to be repaired, I unbolt them, take them to the shop, sand the faces, repaint, reseal, then bolt them back in place. Since each cut out is about 1/2" deep, I can sand and refinish them several time be fore they need to be replaced. Hopefully he will be retired by then. :grin: I will use brass inserts and stainless steel bolts and washers........need to avoid rust here on the Gulf Coast. The sign blanks are 1-3/4" thick. So with 1/2" deep cut outs, I don't have to worry about blowing out any of the mounting holes......plenty of material left between the bottom of the cut outs and the bottom of the bolt holes.
 
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Discussion Starter · #7 ·
Great job Frank . Very impressive looking signs ,and look like a lot of work.The gaps in the D , are those supposed to represent cavities?
Rick, the white sections of the "D" is where I had to tape the "tabs" back that I accidentally cut through. These tabs held the paper in place in the center of the "D". I was talking with a friend while cutting out the stencil and cut right through the tabs. I realized my mistake before I had completely removed the center. Live and learn!!!
 

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Oliver (Prof. Henry)
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Impressive signs, Frank, and I know they were a challenge to carve. Well done.
 
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Discussion Starter · #10 ·
Yes sir, Ted.....I had a full sized stencil made. Then I cut out the letters and artwork, taped the stencil to the board, lightly painted and carved the sign.

The last pic is one of the signs completed.....less the clear coating. The Dr. decided no white paint on the face of the letters.....and I'm glad he did.

Sorry for the pics orientation......I can never get them to post like I had taken them.
 

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Ross
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Nicely done Frank.
 
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Discussion Starter · #12 ·
Temporarily hung so I can locate and mark the mounting holes.
The signs do NOT have any clear coating applied at this time.
The next step is to install the threaded insert for mounting.....then clear coat.
 

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Discussion Starter · #16 ·
BIG X2 IS FINALLY THROUGH!!!!

The third picture shows the back side.......and how I bolted the signs to the frame. I installed 5/16-18 threaded inserts in the back of the signs. This way, when the signs need refinishing, I can unbolt them, take them to my shop, sand and paint and clear coat. then bolt them back in place.

This one was fun....stressfull.....time consuming.....rewarding.....and now......MENTALLY COLLAPSING!! LOL

It's going to be nice to drive by them almost daily and look at them.
 

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