My son wanted a place to hang his super suits for his birthday. I thought about attaching the hangers to the sign itself....... The outcome would more than likely end in a big hole in the drywall and the sign on top of his sister. I'm still in the middle of the hanger, I'll repost when it's complete.
Step 1: Template
Find a design you like and print it out on a regular size sheet of paper. Draw a grid over top of design with 1" squares. Decide what your scale is ( mine was 1: 3 1/2 ). Draw grid 3 1/2" sq. on project wood and then transfer. To get the arcs close I used a 2' adjustable curve from lee valley.
Step 2: Profile
Profile the wings using a rotory rasp ( shown above) and a orbital sander. I built this in two parts ( you can see the seam running horizontally, attached using a domino joiner).
Step 3: Border
Same goes for the border ( 2 parts ). I just thought it was easier to handle.
Step 4: Prep and Paint
I sanded down to 320 grit. The border and yellow backing is one piece the is screwed in to the studs and the batman logo is hung using clip hangers ( 4 in total lee valley ). If you chose to, I also elevated the border and sign by 3/4" to give it depth and for the "glow in the dark" strips I glued on the backside. The boy went ballistic when I shut the lights off!!!!