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.

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Disney’s Frozen Project – Times Square Disney Store

Who wouldn’t love working on a Disney project?  This was a fun project with characters, castles and great Disney graphics. We just completed our work, delivered to our client they added their magic and it looks fantastic! If you are  in Times Square NYC this holiday season check it out.

We started out by vectorizing the clients sketch of a giant snow arch and castle with the “Frozen” logo carved into it. In Enroute Pro we gave the outline shape and texture and designed the accurate dimensions to fit on the store fixtures.293294Now this arch is about 16′ Wide so we cant cut it all at once.  I’ll break up the file and start cutting the pieces.

So to keep the weight down we chose to make the arch out of blue insulation foam.  We started by gluing 4’x8′ sheets of 2″ foam together.  Our arch will end up 8″ thick. Once glued we are ready to cut.

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Once the panels are cut – we cut out a channel on the back to set the PVC piping wich will hold the pieces together. The PVC is set in place and the safety cables are installed and crimped.

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The adhesive is applied and the sides are assembled.

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 Now we’re ready to tackle the bases! These need to be large solid pieces of foam so we cut them in discs that will sit on top of each other then Brian will come in with a sawzall to rough sculpt it. Here you can see Eddie assembling the discs and gluing in place.

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We’ll finish up the other base and start sculpting. Brian got out the sawzall for the rough cuts then the belt sander for the second go around.

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Mark and Kevin doing some finishing sanding.

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Here’s Brian and Greg with their homemade sanding tool – Great for taking away a lot of foam fast.

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Ready for Bondo and Paint!

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While the arch is off to the paint shop we’re busy printing away and building some other cool features for the install.

Here is an 8′ Marquee Gift Tag.

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A GIANT painters pallete.

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Lots of wrapping paper….

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Some cool Mickey Ears….

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and a bunch of other cool stuff.

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And here is the transformation (with the help of our clients amazing design and installation skills)

BEFORE:

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AFTER:

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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!!!!!

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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!

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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.

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

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

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More to come….

Stone Wall Plaque

So our friend and client Julian came in last week with an interesting project. He was looking for a creative way to present a plaque to a colleague as a gift using their logo as the artwork. So we came up with the idea of doing a carved “stone” look.

We started by taking their logo and vectorizing it in Enroute Pro.

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Once we had it as a vector file we are able to manipulate it and convert it to 3D then add stone texture.

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Once we had the 3D all set it was time to cut it. It’s off to the MultiCam 3000!  We’re going to cut it from 1.5″ 30lb Precision Board so that finishing will be fast and easy. Here you can see what the first rough pass looks like along with the finish pass starting.

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Now we’ll have a little fun and add some more stone texture with my favorite texture tool – a spackle knife.

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We are ready to prime using Coastal Enterprises FSC-88 Primer/Filler.

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Then we’ll paint the whole sign black. Here Mark is putting down two quick coats of Modern Masters Black Pearl.

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Now to add the white detail of the logo. I’m going to add paint right into the carving then paint the face of the letters.

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And here she is…

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We’ll add a cleat to the back and it’s ready to hang.

Building Sign – The Athlete Recovery Center – Part 2: Cutting The Sign

So we did some more tweaking of the fonts to get it just right and tested the final design by placing a print on the front of the building. Dan, the client, was happy so it’s on to the 3D portion of the project.

Here we’ve added depth and texture to the design to give it a natural wood feel.

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Now we are ready to cut. I’m cutting these out of 15lb Precision Board HDU on our MultiCam 3000. We’ll then mount the signs to 3mm Dibond for extra rigidity.

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Now we are ready for assembly and paint!

The Alphabet – KDF Style

The Jedi Master of creative dimensional sign building, Dan Sawatsky at Imagination Corporation, suggested we get creative with textures, paint techniques,and sign making and use the alphabet as a study for sample purposes. Thanks for suggestion and the inspiration Dan!

Here is our rendition of the alphabet…

 

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and here is a little bonus of the Alien Queen in metal…

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