Hi, this is my first instructable, even thought I have being
a member for years...

My friend was setting up her new business and asked me to make a sign for her shop. I recently built a diy CNC based upon the Ox Metal design and went about cutting and installing the sign for the shop.

Materials:

Foamlux (expanded PVC)

6mm threaded bar (1.5 meters)

Tex 7 (Tube of silicone)

Superglue

Tools used:

Dill

6mm concrete drill bit

6mm wood bit

CNC router (Could be cut by other means)

Step 1: Cutting the Sign

I used my Ox metal CNC with a Makita Trimmer router model RT0700CX4. I tried and tested several different milling bits from Amazon, I found the single flute bits to work best on the material. The material is black expanded PVC, also know as Foamex.

I used Easel.com to create the lettering and made the large "E" first. The I cut the rest of the letter's out / I was surprised how well the letters turned out, my very first cuts on the machine...

Step 2: Prepare Letters

We were happy with the black color, so no painting was required. To prepare the letters for install, I cut 2" piece's of 6 mm threaded rod, drilled the letters with a 5.5 mm hole in each letter and threaded the 2" piece. I drilled 5 mm in depth, the material is 10 mm thick.

I also used Tex 7 a strong brand of silicone to keep the threaded rod in place.

On the large letters I used 3-4 threaded rods, on the smaller letters I used 2-3. We wanted the keep the large letters out from the wall, so I cut up some scrap piece's of the material, which I drilled to create spacer's. I glued the spacer to the letter with the silicone. The smaller letters would sit flush on the wall, so no spacer's were used.

Step 3: Install

Once I had installed the threaded rods, I placed the letters, face up on a large sheet of paper. I equally spaced the letters and made sure they looked straight. I marked the position of the threaded rod ends on the paper. This paper with its rod position will be used to drill holes on the wall.

Now we positioned the sheet of paper over the entrance to the shop, to get an idea of where it looks best. I taped the sheet to the wall, and drilled 6mm holes per the marking I made on the sheet.

Finally, I filled the holed with silicone and inserted the threaded rod on the letter's.