Bailey’s Project: Day 7 – part 2

Things are heating up!

Brian and Greg are completing final assembly of the sign and working out all of the details of installation.  Wow – what a paint job! Brian has outdone himself on this – amazing! We are ready for install on Sunday. 012

 John is on location with the bucket truck installing the 3″ thick steel sign bracket.007


Bailey’s Project: Day 7 – part 1

OK Its Friday – we are installing on Sunday – St. Patrick’s Day is Monday. Hmm. Pressure is on!!!!!!

Brian has been in the paint shop for days – not sure if he’s seen daylight.  But it’s payin’ off! After all the priming Brian started mixing the paints and spraying. Time is running out but we’re almost there. We have a crew out today installing the bracket on the building so Sunday we can focus on transporting and hanging this 200lb baby. 

The colors are amazing and the finish is incredible. We 3D cut the face of the ribbons and left the accent lines of the font on the ribbon.  This way it would create a dramatic depth when the letters get placed in. Brian hand painted the gold details and the filigree.

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The main body of the sign is painted and its time to attach the front face pieces and the grill.  IMG_3434

The LED’s are inserted and it comes alive!


Bailey’s Project: Day 5


We’ve had several project deadlines over the last few days so it’s been a little hectic here.  But we’re moving along with the Bailey’s Project – fingers crossed for St. Paddy’s Day! Now that he has all the elements of the sign Brian is completing the assembly and sculpting – there will be a lot of sanding. 

Once complete he’ll register all the parts and pin them then disassemble. Reassembly after painting will be smooth having all of the pins in place.

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To add texture to the sign quickly Brian is using a die grinder. What a great tool! 

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Bailey’s Project: Day 4

It’s day four and we are making great progress – the sign is REALLY taking shape.  All the precision board cuts are done and the letters are all completed as well. Brian is hard at work fabricating standoffs, welding, sculpting and assembly. Once the sign is put together and the parts sculpted just right he’ll take it all apart to begin priming.

We cut the “smokehouse” letters out of 1/2″ black PVC.  And the larger 3D Cut “Bailey’s” out of 1″ thick 15# Precision Board HDU. 

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Bailey’s Project: Day 3

 Wow! Day 3 flew by with lots of progress on our Bailey’s project.

The shop is buzzing with activity. We have installs going out the door, the MultiCam 3000 CNC is cranking out dimensional pieces, all of the printers are running with jobs ranging from tractor trailer wraps to art prints to murals and signs, and…. the phone is ringing off the hook!!!!  We are busy.

So even with all of this going on we are focused on the Bailey’s deadline, and the pint of Guinness that awaits us at the end of the project.

The sign is hanging in the workshop and Brian has finished all the welding on the grills AND they are all painted. I love these and cant wait to see them attached to the painted sign.







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I’ve been working on the ribbons and face details.  As an added little feature I’ve taken the accent lines of the font and extruded them. Then I cut a pocket into the ribbon to easily register the letters which I’ll cut separately. 001

 Here is a rough 3D rendering of the large top banner in Enroute Pro. Almost ready to cut! 003


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we’re getting close to completing the CNC work – next up will be the letters – then Brian will be in full assembly mode.

– Steve

Bailey’s Project: Day 2

Day two is underway!

We’ve made some great progress in all areas. Brian’s been hard at work welding up the grill.  It looks incredible and will really make this sign feel authentic.IMG_3266

I’ve been programming the face and ribbons and working out the depth of the overall sign. In Enroute I’ve programmed the basic shape of the ribbon with the text – once I’ve cut it out of Precision Board HDU Brian will do some hand sculpting to remove the “machine cut” look.




Bailey’s Project – Day 1: Countdown to St. Paddys Day

If anyone reading this knows us at KDF you probably know that we love a challenge. Usually the challenge comes in the form of a tight schedule or a difficult design or a slew of creative ideas that need to be quickly conceptualized, sifted through and executed on.  This project has all of the above. It has an extremely detailed custom dimensional sign with LED’s, goosenecks, layer after layer of HDU and it all has to be done by St. Paddy’s Day! We’re going to earn our Guinness on this one!

Last year we had the pleasure of working with our friends at Bailey’s Smokehouse in Blauvelt NY ( AWESOME FOOD!!!!

We designed, printed and installed a van wrap for them. They’ve returned with a bigger and better request. A logo redesign and a custom sign to go with it.

So we started with what we’d love to see in a cool sign then worked backwards to create the logo.  We incorporated everything that was important to the client like the fonts, color and overall theme then we kicked it up a notch.

Here is the logo…


DAY1: Today we kicked off our build by pulling apart the logo and figuring out how to make it. We’ll have two teams on this project – Mark and I will be taking on the task of designing the sign parts in Enroute Pro then cutting them on our MultiCam 3000 CNC. We’ll be feeding the parts to “team two” for fabrication and painting.



This is the first layer of the sign – we are cutting it out of 2″ thick 15# Precision Board.



We’ve created a middle layer of HDU that we’ve cut a pocket into for out steel hanger.



Brian and Greg will be doing the fabrication. They’ll start by making the grill out of 1″ steel tubing. Once the outside tubing is bent around the form it’s off to the welding shop.

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