In this Instructable, I will show you the process that I used to make the Giant Wrench. I have also included the video of the carving and the DXF files.

You will need the following:

CNC Router- I am using the X-Carve CNC

Cad/Cam Software- I used Vectric Aspire

90 Degree V-Bit

1/8" Endmill Bit

1/4" Endmill Bit

Wood- I used a piece of Poplar glued up

Sander & Sandpaper- I used a Oribital sander with 220 grit

Paint- I used some Rust-oleum Bright Galvanizing Compound, I had this on hand, you could use Silver

Rust-oluem Clear Gloss Finish

Giant wrench with Garage lettering.dxf
Download

Step 1: Design

First thing I done was search on Google for some images of wrenches, found one that I liked and made some vectors from it, first photo. I then worked on the vectors, adjusting them until I got the results that I wanted. I worked on the ends first, then the middle section. Added the Garage lettering and a outside boundary.

Step 2: Add Toolpaths

Next we need to add Toolpaths, I highlighted the End pieces and choose Profile Toolpath. With a flat cut depth of .165 inches deep, using a 90 degree V-Bit, while Machining on the vectors.

Then I highlighted the middle section and Garage lettering. Choose the V-Carve Toolpath with a flat cut depth of .165 inches deep. Used the same 90 degree V-Bit and a flat clearance bit for the flat parts of 1/8" Endmill.

For the last Toolpath, choose the outer border vectors and use the Profile Toolpath with a cut depth of the piece minus a few thousandths. I used .790 with my stock .800 thick.

Step 3: Preview Toolpaths

Next I preview the Toolpaths, to see if everything comes out right before carving the piece.

Step 4: Machine

Now place the piece of Poplar in the X-Carve CNC and first carve the ends, then the lettering and middle section. Then I cut the piece out with the 1/4" Endmill.

Step 5: Sand

Now we need to sand the piece, I used a Orbital Sander with 220 grit sandpaper, plus had to hand sand around the lettering.

Step 6: Paint

Then I wipe off the piece real good, and spray a coat of Rust-oluem Bright Galvanzing Compound paint, this is what I had on hand. You could use a Silver color of paint, or your choice. Let dry overnight.

Step 7: Clear

After letting the paint dry overnight, I sprayed a couple coats of Rust-oluem Gloss Clear, allowing the previous coat to dry before spraying another.

Step 8: Enjoy

Now hang the project up and enjoy, I didn't attach any hardware to this, but you could. I hope you liked the this Instructable as much as I did making it. Been working on this project for awhile, finally finished it. Thanks again for checking out my Instructable.