It is hard to believe that it was almost ten years ago I witnessed a CNC router in action for the very first time. I was fascinated with what I saw and simply had to have one! Although I had been in the creative end of the three dimensional sign business for most of my life I didn't really know what I would do with one - but I just knew it could do fantastic stuff.

Through extensive research and LOTS of hands-on practice I quickly found out that my MultiCam router was capable of just about anything imaginable.This journal will chronicle that journey to date and continue each week with two or three entries as I continue to explore just what is possible with this wonderful tool... -dan

Saturday, August 30, 2014

Cookie's Galley

Back in April I created the first routing files for the Skallywag Bay. Now at last it is time to fire up the MultiCam and get going on these projects. Todays sign was for Cookie's Galley, the food establishment for the park. It will feature Cookie of course, the Gruffle cook.

During the sculpting workshop of last fall I had created the sculpt of Cookie for the sign so he was ready to go.

To see how I created the routing file in EnRoute go HERE.  The face of the sign was done as an island fill on the MutliCam. The middle section and back of the sign were done as a simple cutouts.

Before assembling the sign I first needed to weld up a steel frame to laminate inside. I cut the pieces of steel, dropped the long tubing into the slot in the middle section of sign and then used two spacers (of scrap steel) to hold the back of the sign off the table.The two pieces of tubing that were to protrude out of the sign for mounting were then tacked to the interior piece,  The spacers allowed me just enough room to do some tack welds of the tubing. One the tack welds had cooled for a minute I took things apart to weld them up solid

I then put the steel frame onto the back piece and traced around it with a felt pen. 

I then used the air powered die grinder to take out about an eighth of an inch of material to give the steel a bit of breathing room and allow for expansion due to temperature changes.

Then it was time to spread some glue (PB Bond 240) and spritz with water.

The face of the sign was then screwed together. Here it is with the head placed roughly where it will go. Once I do the final shaping and add the woodgrain to the edges of the sign we can dowel and glue him into position permanently.

Then it will be time for paint.