Phil Phelps
05-10-2005, 9:03 AM
I removed this pic from Corey's post on "laminate trimmers". I didn't mean to hi-jack his thread so I moved it to a stand alone. I wasn't intending to post this because the only "wood" involved is the frame for the bottom portion of the sign. This sign began as a picture with dementions of 9'1"x7'6". I priced it as such and when I presented the one unit construction to the clients, it had grown to 134"x110". Needless to say the "one unit" concept was shot. I talked them into 120"x100" and, two peices. Actually it is three peices. I made the "Mission" sign separatly to hang on pinch cletes. It's an all laminate exterior. And that part is fairly slow. There is a lot of trimming and filing. But it is faster and more durable than painting. The bottom is a wood frame, 1 3/4" thick and faced with 1/8" Masonite. I filled the inside with 1 1/2" Gatorfoam. Gatorfoam is a trade name for a styrene board covered with a "melamine" like face and back. It comes in various thicknesses and is light and structually sound. All the layers and letters are Gatorfoam and laminate. The upper portion is a 7"x120" wood frame with a Gator/masontie top. I had to use a latex, 3M, contact cement on the foam edge. Solvents will attack the foam. I subbed out the bells. They are sculpted foam with a poly hard coat sprayed on them. Hard as a rock but weigh about eight pounds each. Letters are Gator with a white laminate face. I used standard grade laminate for the sign and vertical grade for the copy and edge. There are three signs in all. No, I do not own a CNC. Needless to say, I've been busy. I used to post here often, but when I moved into the 1950 house in Feb., 04', I've been AOL from the Creek. I have half my kitchen in the shop floor, and maybe, just maybe, I'll paint the cabinet doors and hutch this week. Some day I'll be back as a regular. You're doing a splended job here, Keith. Thanks.