Vedder Mountain Grille - Part 1

This sign for the Vedder Mountain Grille, (a local restaurant) feature its namesake mountain . We decided to route a hole in the sign, allowing the real sky to show through on top of the mountain.

The client also requested a motorcycle and rider somewhere on the sign as he rides the mountain often... hence the name of the restaurant. We included the motorcycle as part of the sign’s bracket.

Once the design was approved we created the lettering vectors in Illustrator, then imported them to EnRoute to finish creating the file.

This is a very simple 3D file. There are four different routing files, each would be cut twice on the CNC router to make a double sided sign. The inside layers were simple cutouts. The oval and lettering was roughed out with a 3/8" bit and then finished with a final detailed pass with 1/8" bit. The lettering was cut with a v-groove bit.

While the CNC router was busy cutting we were out in the shop fabricating the steel work for the sign. The sign’s bracket was plasma cut by hand.

Once the CNC router was finished, we set about assembling the pieces. First we used a die grinder to cut the grooves for the structural steel.

Then we glued and clamped the sign together. We used Coastal Enterprises one part urethane glue, PB Bond-240, to glue the Precision Board HDU.

Once everything was dry we lifted the two layers into place and welded the sign to the post

Later, we glued on the rest of the layers. At this point you can easily visualize the finished sign. Now it is time to start the hand sculpting.

Dusty's Flying Service - Part 7

Once the sign was finished, we moved it out into the sunshine to photograph. The 23K gold leaf letters absolutely sparkled and in spite of being relatively small they instantly drew the eye. The sunlight played on the textured surfaces of the sign — adding shadows and even more dimension.

The little red plane, roaring through the centre, adds a little drama to the sign. from the back of the sign you can better see the sturdy steel rod that holds the plane firmly in place.

The sign is a great example of how our CNC router helps us create something that would have taken many times longer done by hand. And, while it was largely made by a machine, it looks hand crafted.

Dusty's Flying Service - Part 6

(Gold Leaf Basics — Part B)

Once the size has tacked up, it's time to lay down some gold. Make sure there isn't a strong draft draft or a fan blowing when you place the gold. (It is very thin and it will blow around wasting it unnecessarily.) Take a sheet of gold (still on the tissue paper) from the book and gently lay it into the size. Press it down, burnishing it by rubbing through the paper gently. Lift off the paper leaving the gold stuck to the sign. Move to a new section of the lettering and repeat.

The gold will be a little ragged and uneven but not to worry. Once you have finished a section take a large, very soft brush and go over the letters, gently knocking off the excess gold. The brush actually scratches the surface of the gold and these minute scratches make the gold catch the light and sparkle. The effect is dramatic and amazing. Tiny flakes of gold will fall like snow to the floor. Don't sweat it.

The reality is that the gold isn't that expensive in the scheme of things. This sign with all its lettering only used 32 sheets of gold. In the quantities we buy (by the box) it worked out to be only about $50 worth of gold in total. Furthermore, gold work sets our signs into a class of their own as so very few sign shops offer gilding these days.