We decided we wanted to make a sign for our Swap Meet sale. We wanted to keep with the DIY spirit of howtoengineering.com so we used Wood, Metal, and Tiles for our company sign.
TIG welder setup
Tungsten with sharp point
Safety gear ready
Outline estimated spacing
This is me starting the first weld.
Just the H
Now an O – That was a challenge!
Getting there…
I was so tired by now.
just need .com
Took me 3 hours of TIG welding.
Now to layout the wood using stencils.
I trace them with pencil
I use the table saw to cut the wood to size.
Right on the line! Perfect!
Cutting the other side
I make round corners using a bottle as a stencil.
I use a hand jig saw to cut the corners
Nice round corners
I sand the corners smooth.
I use a practice piece of wood to set the router up.
Here is the edge I want around the sign.
I routed all around.
Nice.
Now I setup the V groove bit on my sample wood.
I cut a few letters as practice.
Now to do the main sign.
I set my height for the tile heart using the sample wood.
I start with a smaller router bit and remove the corner.
This is the start, done on both sides.
I also make a small hole in this small corner.
Now for the larger router bit, setup to same height as small bit.
Tested on scrap wood to make sure it matched smaller bit.
I carve out the top and start to cut out the heart.
Now the heart is carved, and the metal sign fits in.
I setup the V groove bit for a inside decoration for the metal sign.
I do this freehand and it worked well on my sample.
It worked ok on the sign.
Now with the metal inserted.
I added some spray on glitter to add a shine. (Temporary stuff, washes off)
I then use this to prevent the glitter from washing off.
This stuff is made for wood, not metal… but it worked.
Now for lots of sanding.
I start with adding a deck sealer and stain.
Nice.
Now to glue on the metal piece
I use liquid nails
Glue is dispenced.
Glue is now spread evenly
I use a paint brush to remove any glue that shows in the gap.
The sign is left to dry.
We use this to glue the tiles into place.
Its added little by little, and spread evenly.
We make a raised area to lay red beads down.
We start at the bottom
Beads are now on.
We use a piece of glass to level it with the wood.
Now to add in the mosaic tiles
The mosaic looks great.
We now flatten this with the glass.
Nice and level!
It is left to dry
Now the letters are painted in.
WE and DIY are now blue!
We used white grout and added red acrylic paint to add color.
Lots of paint, and lots of mixing to get the right red we wanted.
The grout is spread on and pushed into the cracks between the tiles.
Everything is covered.
Use a rag and remove the top layer.
Wait until its a little dry
Clean with a rag again.
Let it dry again
Now to remove the tape… OH NO! it removed the stain!
We re-coat the stain in the center.
Now to water proof the sign using urethane 3pt to mineral spirits 1pt for quicker drying on first few coats.
Brush it on and let it dry, then sand and re-coat.
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