|FREE Sign 2009
|Welcome to the FREE sign 2009 how to page|
How a FREE sign is made:
First thing is the idea. Dry erase white boards come in handy for this kind of stuff.
I had to make sure that the sign met certain design considerations:
1. the sign needed to be small enough to be carried away and/or fit into most any vehicle and yet still be large enough to be seen.
2. the sign had to be eye catching so that someone will notice it.
3. the sign needed to be made from materials that are cheap and durable. (it's free but still a good value)
4. the sign needed to be self standing
First I drew the sketch on a scrap piece of plywood that had been just laying around waiting to be something. Then I took my trusty jigsaw and cut out the contour.
Ok, so I figured a 2x4 would be a good base to sit the sign into. This grove was done on the table saw, but you could also use a router.
I don't have a router yet, so I used the table saw to make the bevel on the edge too. (naturally the guard is removed only for the photograph and the power to the entire building was shut off too)
In order to make the sign stand on it's own and also fold up I came up with this solution that I stole from a music stand design that my neighbor Tim has. He said that he was going to tell the company that I stole it, but I think he is full of it.
The pivot bolt is countersunk into the datto so that the head is flush, then the pivoting leg needed something similar. The hole for the nut side needs to be large enough to get a socket wrench in there to tighten everything up. I made the nut just tight enough, but not too tight since it needs to swivel. to keep the nut from backing out I peened it against the bolt with a center punch.
This is one of the two blocks that go at either end of the base. Countersinking holes is a must unless you are trying to split the wood.
These are just run of the mill drywall screws that I had laying around to attach the stand offs to the bottom of the base.
Then the base is glued with urethane glue and screwed to the sign panel. Urethane glue makes a mess if you get it on yourself, so don't.
I don't have a picture of it so you'll just have to trust me, but the edges of the plywood were full of holes, I filled them all with two part automotive body filler (bondo). It's by far the best thing to fill holes in wood that's going to be outside.
This is a palm sander (I find that if you sand your palms you don't want to go any coarser than 200 grit) Sanded everything after the filler was completely cured.
A coat of primer, then onto the paint. I could see the pencil through the primer, so I just used that as a guide to paint by.
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