I have been helping a friend build a bar on the back room of his garage, but he's an in demand mechanic and his hectic timetable wasn't giving me the usual level of fix I need from a project, so while I waited for him to pull his finger out I made him a bar sign.
Kids dragon cup
Sand paper and belt sander
Cordless drill driver
Router and bits
Dremmel rotary tool
Deep mahogany wood stain
Metallic gold paint
Step 1: Planning the Sign
I cut out the corners using a jigsaw an cleaned up the cuts with sand paper. To transfer the lettering I used a mix of free hand and a crude debossing which just involved me drawing over the text outline to leave an impression in the soft wood underneath.
Step 2: Carving the Lettering and Routing the Edge
I cut the outline with the blade held at 90 degrees to the wood and then cut parallel lines with the blade at 45 degrees about 2 - 3 mm apart. This cleared it quickly. The shadow lines on the lettering were quite tricky, but I just used the same method of holding the blade at a 45 degree angle with closer cuts.
I did loose a few chips of wood, particularly between the edges of the lettering and shadow lines but I told my self that it gave the sign rustic character, and didn't obsess at all about how it would effect the painting later on.....
I used a very small, very smooth mounted point on the dremmell to smooth down the cuts in the lettering. Then put an roman ogee edge on the sign with my router, then I had a brew.
Step 3: The Hanging Bracket
It was time for me to go to amateur town again, I took a hammer and chisel and slowly, carefully, methodically, cautiously hacked the hell out of it until I could just wiggle the length of timber in. It was a nice fit but I decided to screw a little support underneath just in case at some point in the future somebody decides to start a Drunkolympics and do pull ups on it (P.S. I'm trademarking Drunkolympics).
I offered up the sign and fitted two hooks for the chain. I then gave it all another fine sanding and three coats of stain.
Step 4: Painting the Sign
I used a fairly cheap metallic gold paint and acquired my daughters paint brush set. I found that once I had loaded the bristles with paint if I squeezed the firmly in a sheet of kitchen roll it gave me a nice flat point to get in all the nooks and crannies. It also gave me a condition I have named disco finger, double up that kitchen roll or you will have sparkly finger tips!
The small unwanted chips turned out to not be a problem as the viscosity of the paint stopped it from spreading into any voids. I was planning on giving it two coats of gold but I was happy with the finish and after not having any stray drips didn't want to push my luck and risk the greatest spill since the Exxon Valdez.
Step 5: Ta-da!
In the photo it is just fixed to my shed as Boswell's Bar isn't ready for the grand opening yet.
If you have enjoyed this instructable please could you vote for it in the wood working contest!