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 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

Texture and Gadgets

We’ve been busy but have still found some time to work a little every day on our Mechanical Fish project. While Brian is working the mechanics of the tank I’ve been adding fun little elements to the design and creating some cool textures and “mechanical” parts.

Here is the control panel – We’ll be adding switched and a panic button soon. But it gives you an idea. Working lamp? What kind of sign is this!!!!!


So Brian has set our mechanical fish in the tank. we have some cool propellers on the back and the LED’s are lighting up the cabin and the button eye. No small task as this fish is submersed in water.  Next step is to install the pistons to open the door!


I had to get KDF somewhere on this sign! We didn’t want it too obvious so in a fun way we’ve placed it on the top of the periscope box.


We’ve finished the back of the box, all out of 15lb Precision Board HDU.  The face was cut out of 30lb.


The front took a lot more time. All 30lb Precision Board HDU then I used Magic Sculpt for the organic material in the corners.


More to come….

The top of our chest – mechanical fish project

It’s time to put the top on our chest and finish up the base of our sign. I cut the top, two sided, out of 1″ 30 lb Precision Board on our multicam 3000.

This was a tricky one. First I cut the bottom side and used a hatch fill to remove a 1/2″ pocket all around so the piece would fit snug over the sides of the box.

Then I routed a 1/8″ deep seat on the spoilboard to hold the inside part of the cut piece. I set the piece in place and I’m ready to add my texture on the other side.

Once I routed the the texture it was time to cut the piece in half because one side would be removable. Once in place we’ll add the wrought iron metal over the seams so you won’t know the panel is removable.




Completing the Structure – Mechanical Fish Project

All the welding is done. The leveling feet are on and the steel structure is now complete and painted. All I have to do is cut the acrylic tray for the top tank and we are done with stage 1!


For the base of the top tank we used 2″ acrylic – overkill maybe – really cool custom acrylic fish tank tray – definitely!


I designed the cut in Enroute Pro then sent it down to the Multicam to do all the work.  We screwed some MDF to the table to keep this block in place. 1/2 an hour later – a perfect cut came off the table!


Perfect fit!photoft4

A quick leveling and we are looking good. Onto the next stage!


Finishing the Dragon – KDF Studio Sign

Our little dragon is now complete! Our last step was painting him.

We got started by priming with Coastal Enterprises FSC-88 WB HDU Surface Primer. Two quick coats and we’re ready for color.

We love the Modern Masters Metallic Paints – for our dragon we started with the silver as a base coat. It dries fast so we were mixing up our glazes immediately and ready to paint it on quick. First was a red glaze then we finished up with a black glaze. The whole process took about 20 minutes – we got the exact result we were looking for. This guy looks old and weathered but still strong and a little scary!



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we are on to final assembly of the sign – the next post will be the completed sign – all lit up!



Halo Lit Custom Channel Letter Sign

Our friends at Crestron Electronics hired us to create a front desk lobby sign for their headquarters.  We’ll be creating custom channel letters with high gloss black finish mounted to a satin metal box and lit with LEDs.  The challenge with this sign was that the box was about 110″ long and our cutting bed was only 96″. So with some creative maneuvering we were able to make the cuts.

Here we are cutting the letters for our sign out 1.5″ 30lb Precision Board.  These will be real heavy duty letters and the 30lb density foam will allow us to get a nice smooth finish. You can see the drill holes for the screw posts which we will use to mount the letters once complete.  We have also hogged out a channel to allow for our LEDs.

cnclettersHere is cut one for the back side of our box. As you can see we cut only the first part – we then had to move the sheet of dibond and reregister it to the MultiCam table to allow for the second cut.cuttingbox2

Complete! and ready to mount the letters.


Brian has all the letters back from the paint shop and ready to go.


It’s time to install the LEDs, wire each letter and logo element then and then wire up the box.

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Here Mark is measuring the LED output and calculating the final letter height.

markThe letters are going on nice and smooth but there is still a lot of wiring to go.


All done and ready to be installed.