In this instructable I want to step it up a bit by making every element dimensional and textured
Step 1: Cutting the Parts
This material is 1 inch thick and has a density of 18lbs per cubic foot. They have material ranging from 6 to over 60 lbs pcf and in thicknesses 1/2" to 12" and over. However you could just as easily use the pink or blue insulation foam found at your local hardware or home improvement store.
This photo shows my paper patterns spray glued to the foam and my jig saw ready to rip, if you have a cnc router or maybe a LASER (this probably cant be cut with a laser but this is my submission for the epilog laser), this step could be automated, you work out the details here.
I have a jig saw and a dremel, so thats what I used.
You can draw right on the board or project a pattern or, like I did, set it up in coreldraw and print out on a plotter. You can even use your laserjet or inkjet and print and tape together your patterns, use your imagination.
Step 2: Glue It Up
Let it dry over night and your ready to shape it.
Step 3: Ready to Shape
Step 4: Shaping the Skull
I used lots of reference photos of skulls found on the internet to get it somewhat right but still took a little artistic license, I wasn't going for accuracy here, just a cool sign.
Step 5: Epoxy Coating
Using the urethane foam, this step was not absolutely necessary, but I did carve away a little too much in some areas. If your using the insulation foam you could also use bondo or snow seal roof coating to build up areas and add texture.
Step 6: The Signboard
I cut the lettering from some 1/2" material I had leftover but could have used plywood or mdf,
and the layer the lettering is on is 1/4" sintra pvc but could have been plywood or masonite, whatever you have.
Step 7: Prime and Paint
Step 8: Add Paint
I routed a 1/2 in. deep hole in the back and fastened a french cleat for hanging
See more of my work at:
and my blog at:
Step 9: Contact
you can see more of my work at the links below and if you have any questions, please do not hesitate, I will help out where ever I can. https://www.facebook.com/pages/JP-Graphics-Artistry-and-Design/230729986988?ref=sgm http://jonpetermanartistry.blogspot.com/ http://home.budget.net/~signjon/Home.htm contact Coastal Enterprises for samples and information http://www.precisionboard.com/pblt.php