Fetch Sign – Woof 6 (the final Woof)

It’s our last day with the Fetch Sign – we are finishing up the details and doing the final assembly. All the parts are painted so Peter now has to complete the pins and glue all of the elements in place – I’ll do a little welding and we should be done.




273 274 281 293 294We really want to make the collar ring look as real as possible so we shaped a 4′ length of  steel rod inserted into the hole in the dog tag and welded a plate on it so we could easily secure it to the structure.  We ran a bolt through the top of the sign to hold it in place.



Here she is – Ready to hang!


It’s time for dinner. Hmm where should I go…..



Fetch Sign – Woof 5

All the parts are completed and they’re off to our paint shop. We use a PPG Waterborne Automotive Paint System which gets great results and is much less harmful to the environment.

Holin, our master painter,  has prepped the metal parts in our bead blaster, he then cleans them with a metal prep and  they are ready for primer and paint.



IMG_3979 The foam parts are lightly sanded and we brush on a thick HDU primer. Two coats of the primer then paint.






Columbia University FSAE Team Car

Again another really fun project with our friends at the Columbia University FSAE team.  What an impressive group of students! Check out their site here.

We worked with the team engineers to create the molds for the cars body out of Precision Board HDU.  The team then molded the carbon fiber panels.  Once completed they sent us the panels for final finishing where our guys wrapped all of the parts in a black brushed metal vinyl.  All of the logo and number decals were then created and installed.

It really turned out great -Congratulations to the 2016 team and best of luck!

Oh and thanks for the tie!

– Steve


Fetch Sign – Woof 4

Today we are fabricating the interior frame of our sign. We are using 1″ Square steel tubing.

We’ve pocket a raceway into the back of each sign panel.  Peter is setting the steel pieces in place, we’ll tack weld them inside the sign for a perfect fit then take it out and complete our welds.


Untitled-2Here it is all welded up and ready for assembly.




Fetch Sign – Woof 3

Now it’s time to cut the elements that make up the face of the sign.

126The first element is the 3D bone which will have the Fetch name contour pocketed about an 1/8″ into the surface. Our rendering shows the layout and depth of the lettering.


The bone is also carved out of 2″ HDU.



We’ll then inset painted aluminum letters into that pocket for a real nice effect. This will allow us to easily have a different paint finishes on the bone and the letters.

We are cutting the “tag” face out of .063 aluminum.  The text will then be cut out of the aluminum – when glued in place we’ll see the background color of the sign panel come through.

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And here it is! almost done – next is onto the welding of the frame and mounting system.






Fetch Sign – Woof 2

Files are ready! – our HDU is on the MultiCam table and we’re ready to cut. We are going to end up with a 3″ sign panel once the two halves are glued together so we’ve planed our 2″ HDU down 1/2″ then cut the face.

We’ll insert out steel tubing, glue the panels together and our panel is done. Now it’s on to “The Bone”.

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Fetch Sign – Woof 1

It’s an exciting day here at KDF. We were asked by our good friends at Fetch Bar & Grill in Warwick, NY to update their sign based on a new logo that was just refreshed by our favorite designer, Nanette Hoey.


After some quick sketches we designed the internal frame that will be made from welded 1″ steel tubing – this will be incredibly strong and make for a very simple installation.


Our files are created in Enroute Pro and prepped for cutting. We like to have all of the elements assemble in 3D before going to cut to ensure it’s exactly what we want.

New Bone closeup

New Bone Side view

Next step is to start cutting! Stay tuned.


Wright Family Farm Sign

We were very excited about this sign. Our friends at the Wright Family Farm in Warwick, NY needed to replace an old sign on the main road in front of the farm. This farm has been around for over 100 years so we felt very privileged to be involved.

So we stepped in to help with the task by creating a new design that would incorporate everything they had to offer. Nanette jumped on the design and came up with a wonderful sign design that everyone was extremely happy with.  Now we have to make it….

Single Panel-small

We had to come up with a way to get the background detail in while keeping the sign dimensional. It was very important to make it really stand out for people driving by. We decided to UV print the details of the back to dibond then mount dimensional letters to the face.


Peter takes the 2D artwork and converts to 3D in Enroute Pro. Then we are ready to carve the rest of the sign in two parts. we then glue them together with the hangers installed.


Off to the paint room where Holin will paint the sign with a  latex a enamel.



A little bit of assembly and we’re ready to deliver.

Best of Luck with your new sign!

– Steve

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Sign Shop Sign

Our good friend Robin from Foley Sign Shop in Orangeburg, NY was in the market for an oversized dimensional sign at her great new location. We were happy to work with her on it and had a little fun with her great logo.

Foley Sign

The bed on our Multicam 3000 is 4’x8′ – the sign will be 5’x8′ so we are going to have to piece it together. We are cutting the Palette out of 2″ 15# Precision Board HDU and the letters out of 1.5″ 30# Precision Board HDU.

To lighten the sign we hog out some material.




Once We’ve assembled the palette we cut the letters and other elements. The Foley text is cut from PVC which we’ll pin mount floating off the surface of the palette.



We test all the parts and we have a perfect fit! Time for paint.

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I guess this is the view from the sign face….

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One more coat of color, some details and gloss coats to go!


John got it installed in no time.




Good luck with your new sign Robin!

– Steve