Pearl River Saloon – CNC Phase

The CNC Stage is here – we have all of our files designed and they fit together (on the computer) and we’ve added the textures – we are ready to lay down our precision board HDU on the MultiCam 3000 CNC to start cutting.

Text on CNC

Text on CNC

We started with the letters for the sign first – these were the easiest cuts so we got them out of the way and right over to paint shop.

Dirt on CNC

Dirt on CNC

On to the heavy 3D cuts of the terrain below the tracks. we took a leap and decided to cut every part separately starting with the terrain, then railroad ties then the rails. this would allow us to build up the base for a realistic look and also give us the flexibitliy to paint the elements separately.

Railroad Ties

Railroad Ties

We’ve cut the ties and they’re looking really good.  The detail on this sign will be insane – and alot of fun to look at from up close. after some quick calculations we’ve realized the sign will be 32 feet long!

The Saloon Cut

So we have our terraine, our ties and our tracks we’ve cut all of the letters and it all fits together. So we’re done!  Oh wait – the trains….

Engine Screen Shot

I’ll back up a bit. we started here – I brought my 3D Source file into Enroute Pro – did some scaling magic on it and created my cut files.  Because we are working with 2″ Precision Board HDU  I had to slice it into 3 layers – per side! Yes thats right – each engine is 6 layers of 2″ foam.

Engine - First Layer Cut

Engine – First Layer Cut

We cut each layer seprately then during the assembly process glued them together.


So here is two of the slices -this is when it gets exciting. We’ll now cut the other side of the engine and piece it all together.


After several hours of sanding, cutting and assembly Brian has the two train engines ready for primer! Onto the Tender cars.

Tender Cars

The tender cars were pretty simple cuts made from two layers of 2″ HDU glued together. The tenders cars are key elements of the sign and will allow us to add some real nice details once we start painting.


Another fun little detail is the coal on the tender car. Here i’m hand carving the basic shape then Brian will add another layer of detail and off to the paint shop for Mark and Brian to work some magic.