I am a big Ford fan, especially Mustang's. So I created a Mustang sign to hang up in my Garage, I also carve a Camaro sign for a buddy of mine. Hope you enjoy my Instructable. You will need the following:
CNC Router ( I am using the X-Carve CNC)
Cad/Cam program ( I am using Vectric Aspire)
Wood ( I am using a piece of White Pine 28" x 9.5" x 25/32")
Minwax Prestain wood conditioner
Minwax Ipswich Pine Stain or Minwax Dark Walnut stain
Black Craft Paint
Rustoleum Clear Gloss Finish
220 grit Sandpaper and Sander
Step 1: Design
I opened Vectric Aspire and came up with a design, I decided to change things up a bit. Instead of going with a standard rectangle sign, I wanted something a little unique. This is what I came up with, hope you like it.
I first design the outer shaped, then came up with the inside border. I added the Mustang name and EST 1964. Then for some effects, added some Fake Bullet holes. I made the Toolpaths, then exported the G code.
I imported the G code into USG ( Universal G Code Sender) to send to the CNC Router.
Step 2: Keyhole Slots
I fasten the White Pine stock into the machine, with the backside up. I made a separate file in Vectric Aspire for the Keyhole Toolpath. Installed the Keyhole Slot cutter into the router and made the Keyhole slots. I made 3 keyhole slots, one in the center and the other two on 16" centers. This will give you 2 options for hanging.
The reason I made a separate Toolpath, is because I ripped several pieces of stock, not all the same size. Done all the Keyhole slots, before changing cutters, it saves a lot of time.
Step 3: V-Carving
Now I installed a 90* V-bit, carved all the lettering first. Then carved the border and carve the Fake bullet holes.
Step 4: Drill and Cutout
Next I installed a 1/4" Downcut Endmill cutter, first I drilled holes where I v-carved the Fake bullet holes, then Cutout the profile, leaving tabs to hold piece together.
Step 5: Paint
I then painted the Lettering with Black Craft paint, but I have found a better way to do this.
When you paint this way, it can bleed into the soft White Pine. I made another sign, this time a Camaro one, decided to Stain and finish it first. After it drys, then paint the lettering, be sure to have a damp cloth ready to wipe off any that gets on the top.
Step 6: Sand
Sand the entire piece with 220 grit sandpaper.I had to hand sand certain areas.
Note, be sure to blow off real good before next step.
Apply Minwax Prestain wood conditioner, let set for a few minutes. Then apply your choice of stain. I first applied a coat of Minwax Ipswich Pine stain, but I didn't think it was dark enough. So after it dried, I applied a coat of Minwax Dark Walnut stain, let it set for a few minutes and wiped off the excess.
Note I done this for the Mustang sign, but later made a Camaro sign, same shape.
I finished it first before painting the lettering, it turned out a lot better. After the paint dried, just lightly sand the top again with 320 grit sandpaper and applied Clear Gloss finish
Step 8: Enjoy
Now that we can enjoy the finish product. I made 2 signs, one for the Mustang and the other for the Camaro. I stained the Mustang with Dark Walnut, while doing the Camaro with Ipswich Pine satin. They both turned out great.
So you can decide yourself, if you want to go Dark or Light on the stain. The lighter version shows off the lettering better. You could also paint the lettering a different color.
Thanks for checking out my Instructable, hope this gives somebody a idea or too.
If you like my Instructable, you might check out my youtube channel, I post a new video every week. Click here for my channel