[Wooden Dreams]

Anyone here ever tried routing a sign out of plywood? Thought I'd give it a shot. As might be expected, it was tear out city. 2nd pic is a close up of a spot I lost a literal entire letter to tearout lol. Lots of other spots I lost serifs and whatnot. Hope y'all enjoy. Peace and coconut grease.
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To start with, Plywood is notorious for tear out. Even with a downward spiral. Doesn't matter which router bit you use. you will get tear-out with plywood. I would do this project with a wood panel not plywood. If this was a wood panel in stead of plywood. You still get some fuzz type edge which can be sanded smooth. But plywood always expect tear-out!!!

A downward spiral bit pulls the cutting edge downward. Verves a up-cut spiral bit which which pulls up the grain to help remove the dust. A straight bit plows though the cut. With a up-cut or straight bit, expect tear-out on plywood.

If it was me doing this project with plywood, I would pretreat the surface to help prevent tear out. I would use Gorilla Wood Glue (it does not foam-up). I mean, spread Gorilla Wood glue over the entire plywood like a paste wax. This will fill in the fibers and bond the wood fibers together. After the Gorilla Wood Glue is dry or cured. Then route the sign. This will greatly reduce tear-out. After your done you can paint your sign or use a belt sander or orbital sander to sand out the glue surface.

Using Gorilla Wood Glue like a paste wax finish, is also a good indoor use as a finish. And you can use a wood paste wax finish over the Gorilla Wood Glue if you like.

If this was a wood panel in stead of plywood. You still get some fuzz type edge which can be sanded smooth. But plywood always expect tear-out!!!

This I did on tongue & groove pine. All the recessed areas were painted in.