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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Custom Logo Sign

Oh how we love our friends at Jura! Not only are they wonderful people but they make the greatest coffee makers on the planet!

As they are building out their new headquarters they requested KDF to fabricate a large logo for the reception area.This logo is approximately 4’x8′.

We are making it out of 1 piece of 15# Precision Board HDU which is 2″ thick. We remove excess material from the back to reduce the weight. Once complete we’ll pin mount it to the wall.

After cutting the logo we spray a coating of AquaResin to give it a nice hard shell and to seal the foam. A quick sanding and we have the finish we need for painting.



Two coats our PPG waterborne primer.


And then color….

110  Once the color has dried we applied a satin clear coat.103  And we are ready to install!


All done. Best of luck in your new headquarters!

(I need to go get some coffee)




Fizzy Lifting Soda Pop Candy Shop Sign – Part 3

We are getting close. Brian’s been welding, building and painting away. Now that he has all the letters done he’s moved on to the sign faces. these will be a bright red and will really stand out at this little corner shop.

He started by welding the inside frame of the sign.  This will make it incredibly strong.


IMG_4104Now back to the sign faces. Using our Matthews Paint system Brian matches the clients red and preps the paint guns. IMG_4107Several coats of color are put down to get a real nice, and strong, finish.

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Ready to clear coat and assemble!



Fizzy Lifting Soda Pop Candy Shop Sign – Part 2

We’re ready for paint.

Its time for Brian to work his magic. He’ll start with the letters then set them aside once complete to work on the sign panels.photo 1Once the letters are primed he lays down the PMS matched color. He’s using a Matthews Paint System.

photo 3 Using an airbrush technique, Brian lowers the pressure on the gun to stipple paint the letters to match the logo design.photo 6Here is the final logo before we attach it to the sign face.photo 7

Fizzy Lifting Soda Pop Candy Shop Sign – Part 1

Some jobs are fun from the beginning to end. My family and I were recently at a great new candy store that opened up in our town – Fizzy Lifting Soda Pop Candy Shop.  The store is as great as the name and if you’re ever in Warwick, NY you have to stop in – they have every candy you can imagine and more.

We had a nice conversation with the owner and wished him luck then he mentioned he was in need of a sign – so we sprung into action.  They have such a great logo, a bottle cap and a fun font. I told him I’d love to take on the project.

So here is where we began – a very nice logo just screaming to be produced as a dimensional sign.


We got started right away using Enroute Pro software to  create the dimensional sign. the overall dimension will be 42″ round. The Sign will be double sided and hang on a nice scroll sign bracket off the front of the building.


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Once the 3D logo was completed. It was time to start cutting. We started by cutting the details of the sign face out of 1″ and 1/2″ White PVC.732731We are using 15lb – 2″ Precision Bard HDU for each sign face with a 1″ layer for our inside frame.   791


Everything is now cut and ready for assembly!




The Amazing Spider-Man 2 Sign

Another super fun job! The Amazing Spider-Man 2 sign.

This sign will hang at the Disney Store in Times Square. We cut the larger letters out of 1.5″ Precision Board HDU and the smaller letters from 3/4″ PVC.  We then cut the face of the letters from 1/4″ PVC.

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Brian then painted the red part of the letters with Metallic Red paint then airbrushed the gradation onto the face – WOW I love it.

Rad wrapped a piece of 2″ Gator Board with Avery Car Wrap vinyl – front and back. Mark and Greg took it from there to complete the assembly and install the threaded rod hangers. Great job everyone. Can’t wait to see this movie! – Steve

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“Robots” Sign – Complete

We’re coming to the end of the “Robots” project. I’m doing a little painting in place as it hangs in the wall.  First I’m going to paint the “guts” of the letters – then age them a little bit. This is a Modern Masters Metallic Copper.  I’ll then do a glaze of Black Pearl over the copper. Once dried I’ll rust out the metal clamps.

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The last touch is to dry brush some pure silver back over the face of each letter.


Final Assembly is complete, LED’s are on and my “faux” robotic arm moves back and forth when the motion sensor is triggered. All I have to do is tuck away the wires and this baby is done. This was a lot of fun!

Hmmm what to do next?

– Steve.

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Rise of the Machines

I’ve been obsessed with robots for the past few months. Researching and coming up with processes in our shop that I can one day have a robot perform… Yes everyone thinks I’m nuts. I’ve even been playing around with our home vacuum cleaner robot in hopes of “taking control” of it. Not sure of what it will do just yet but I’m getting there.

So in honor of my obsession I started a little side project of creating a “robots” sign.

photoI started sketching an idea and got so excited about it I ran to the computer and began drawing it up in Enroute Pro. I decided to keep it very simple – i’ll have the word “robots” sitting atop a rover robot with two robotic arms hovering above the letters – one will be placing a letter into position. I also want to incorporate some type of movement in this sign so I’m experimenting with a motion detector and a motor to simulate robotic movement. Ok not so simple. But this will be fun and it’s my obsession – so here we go.

enroute sketch

I’ve cut the letters out of 15# Precision Board HDU

Now its time to cut out the robots that will stand behind the letters. I’m cutting them out of 30lb Precision Board HDU on the MultiCAM 3000. These guys will be large and heavy duty!


077 Once cut I’ll glue them together with Coastal’s PB Bond-240 HDU adhesive. I’ve also inserted a cable which will hold up one of the letters. Once dry I’ll sculpt on some



I’m doing the back panel out of some scrap MDF and I’ll paint to look like rusted steel. I’m getting an idea of the layout. I think I want it a little more robust.

011 I’ll get everything primed while I’m figuring out the assembly. I’m using Coastals FSC-88 Primer – 2 Coats. It works great on the MDF as well.


After the priming is done its on to the painting.  I’ve painted the backer with a faux iron paint from Sophisticated Finishes which I can then rust out.  It’s such a simple process and the results are amazing.

009 While the second coat is still tacky I spray on the Green Petina Solution and wait.  The finish rusts before your eyes.


I’m using the Modern Masters Silver as the base coat for my letters.  With a glaze over the top.014

017 Pre-assembly is complete. Now we are going to hang it and do some more painting and LED work.