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.

270272

280

 

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.

296

300

Here she is – Ready to hang!

302

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

-Steve

 

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.

147

The bone is also carved out of 2″ HDU.

149

152

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.

142 143 145

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

312

 

 

 

 

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”.

IMG_3565 IMG_3567

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.

189

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.

InternalFrame

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.

IMG_1779IMG_1839

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.

IMG_1769

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

IMG_1780

IMG_1835

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

Best of Luck with your new sign!

– Steve

IMG_2041 IMG_2042

 

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.

078

082

079

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.

089

 

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

094 110 111 113 127 128

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

131 166 215

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

Capture3

John got it installed in no time.

Capture2

Final1

 

Good luck with your new sign Robin!

– Steve

 

 

Adding a little character to a sign

When working on larger projects it’s the little details that really make the difference for both the client and for us! Our current project is no different. We are creating a “themed” environment for the Fox Island Creamery & Café in Hewitt, NJ.  We’ve  created a nice little storyline and have developed some characters which should make the experience fun for both the kids and parents.

This sign is for a little beaver character that we created and his boat company. The Chubby Beaver Boat Building Co.

We started with a rough sketch, now I knew we would need a boat, a beaver and the back of the sign. So we started there.

Peter worked directly in Enroute Pro to create the shape and used some fun font styles for the carvings. We carved the sign out of 15# Precision Board HDU on our MultiCam 3000 CNC. Once the CNC was done with it’s job Peter hand carved the edges for the “beaver got to it” texture.

 

sketch

064

 

065

 

 

We sealed the foam with Aqua Resin, then primed and spray painted our base coat.

082

Using latex paint we painted two coats of a darker glaze to get a nice aged look on the wood.086090

Now are sign back is complete and its time to move on to our beaver!

I’ll carve the basics out of 15# Precison Board so I used Mudbox 3D Software to create the body and facial structure of the beaver. Once carved I used Magic Sculpt for the details.

067 069

beaver

Hmm, I think my little guy could use some glasses. I’ll use the 3D printer for this little detail. I printed  2 pairs different sizes, the larger ones look best.

007

We most definitely need a boat for this sign. This is a perfect task for our 3D Printer as well. I found a basic 3D boat online – downloaded the file and sized it perfectly to fit our beaver. 4 hours later we had our 3D printed boat. I love technology!

IMG_1423

075

A few more details and paint and we are all done – Can’t wait to hang it!

IMG_1438

Complete

I’ll take a Wrap and a Giant Hot Dog Please

This project allowed us to meld two of our skills, vehicle wraps and 3D Sign Making,  into one “unique” looking vehicle.  Our client Callahan’s Hot Dogs in Norwood was in need of a new vehicle wrap to match their now famous Hot Dog Truck. So Nanette dove into the design then Dan called and asked… “Can you build a giant hot dog for the top of the van?”. Of course I said yes

This is how we did it.

First the new design was created for the wrap. As the guys are working on this we’ll have the guys in fabrication building the hot dog.

Callahans-Proof Small

 

We started with the logo and converted it into a 3D file in Enroute Pro. Then sized it up and split it into two parts. We’ll cut the hot dog in slices so we can build a “skeleton” inside of it. This is important – we need this to be strong and solid as it cruises down the highway.

282

Peter has the foam pieces laid out and will begin building the aluminum structure that will hold this all together.

286

 

 

Meanwhile…. back in the “wrap room” Rad and Greg are cranking out the install.

297

292

296 293

We are really customizing this one – all lettering has been removed from the van and we’ll replace them with the name of the van “Minibeast”. we also removed the Ford emblems and fabricated custom emblems that tread “Since 1950″. we cut the letters of out PVC and will paint them metallic with our PPG Paint System.

294

The emblems are cut from PVC then painted metallic. We then printed the graphic directly to the emblem plate.   Once printed we clear coated them.299 300 303

329

Peter has the basics done and he’s ready to test the sizing of the hot dog. 309 318

I’m in the paint room customizing the hubcaps!

328

331

332

334

 

Dan stopped by for an inspection of the wrap – He’s a little anxious to get that Callahan’s hot dog on there! Don’t worry – it’s coming.

345

Holin and Peter have the dog coated with AquaResin, sanded and ready for paint.  We’ll spray prime it and paint the base color then hand paint the details.

377

391

400

 

403

410

Uh oh – can’t get it out the door…. No we got it.

417

Time for the install.        433 442 All good.  (now we have to light it up). And again – I’m hungry.

551

543

– Steve

bfree Sign: A Dimensional Sign of Metal and Wood (or maybe not)

I am lucky enough to live in the great town of Warwick, NY – we have wonderful restaurants and shops and its a destination for many people on weekend getaways. There is a new trendy shop opening, bfree and we were lucky enough to be called to help with her “new” look.

The clients logo needed some tweaking and unfortunately wouldn’t work on the sign.  We started by taking the logo and reformatting it to match the “feel” of the store and to better represent what you would see inside.

Our graphic designer Nanette jumped in and began creating a new logo which would incorporate wood, brushed metal and copper.

2015_bfree_sign01

Client loved it – now its time to make this baby!

We began with 15# Precisionboard HDU at a 1.5″ thickness. This will allow us to get all the elements, except the bfree letters on one panel.  We carved the brushed texture and branch into the background and the wood texture of the frame using our MultiCam 3000 CNC.

595 599We drilled holes and cut pockets for our lettering which we’ll make separately as a two part letter.  605 While the machine was working away Peter experimented with the some techniques to create a realistic copper finish.

603We’ve sealed the foam with a coat of AquaResin and and primed. ready for paint!

001

We are using Modern Masters metallic silver as the base coat for the brushed metal. we’ll then add several glaze coats of latex color over it. When the sun hits it during the day it will shine like real metal and at night the overhead goosenecks will really bring out the metal finish and texture.

003

011

While Peter is painting the silver Holin is in the paint booth painting the letters. We’ve carved the copper “swirl”  texture directly into the PVC cut letters for additional texture. We’ll then mount the 1/4″ Copper PVC textured face to 1/2″ black PVC for dimension and to also add some contrast.

006

 

013

017 018 023 024 The letters are done – we’ll take them off and focus on the wood frame.

The latex base coat of the wood frame goes down then two or three coats of darker glaze. We now have a nice contrast of colors against the copper and black letters.

026

 

028

All painted – ready to go on the truck for the install.

031

 

171Installed and lit and looks great! We wish bfree the best of luck with your new location.

-Steve