The carousel sign I posted yesterday is to be mounted to a sculpted tree. Today's task was to glue up the four layers of the carousel sign. The horse itself had been sliced into two layers to fit into inch and a half thick Precision Board. I also cut two other layers from 3/4" thick board. One had slots cut into it to accommodate the 5/8" steel rod frame and the last layer would serve as a backing to seal it all up. We would use the PB Bond-240 one part glue made by Coastal Enterprises. It is spread on the piece and then activated with a spritz of water. It expands slightly as it cures which means it squishes out a little on the edges. This is easily sanded (or with the die grinder) off when we prep our signs.
If you look at the next photo carefully you will notice lots of details. I measured each rod to go into the routed slots (measurements are noted in red felt pen) I then cut bars to length and placed them in the slots and tacked them up with the MIG welder. I then pulled out the assembly and welded it all permanently. The next task was to weld on the two mounting bars perpendicular to the frame. These would be poked through the backing and welded into my tree.
I'll spend a half hour or so with the die grinder to take off the excess glue, even up the sides and texture the back. Then it is off to the painting department. The crew is anxiously awaiting...
-dan
