Need the Pros help on Monument Sign

[sigmagraphics]

Hey Guys,
I've been reading these forums ten times a day since I joined. I have owned a sign shop in Savannah for about ten years now. Mostly vinyl applications. With the wealth of knowledge you guys have shared, I'm ready to tackle my first monument sign order. Its about 4ft x 5ft. I don't want to sub it out. So, i need you pros to help guide me on this first order.
1. I have a company in town that over purchased some Owen Corning Foamular 250. I can buy some 3inch x 48inch x 96inch sheets for $35. Is that a good deal and would you reccomend this for the core of the monument sign. Also, could someone reccomend the correct bit to use for
cutting. I have a 63" x 99" cutting area on my bed. From the bottom of my router collet in the highest position, I have about 6.5 inches to the spoil board.
2. I plan on sandwiching two sheets of MDO between two sheets of Extruded Foamular 250. This should make my sign eight inches thick. I will cut 4" cavities in foam for pvc sleeves.
3. I haven't solidified which hardcoat I will use. I see that some don't reccomend styrospray on anything but white beadboard. I've been using
2 part epoxy for some wood projects. Just don't know how well it would work for vertical application. I was hoping to use a spray of some sort.
4. Part of the sign will have a faux brick finish. Any reccomendations of supplier for these. BTW. Any of you Pros can visit anytime.
5. I want to try out UltraCrete texture coat Joe reccomended from SW. Plan on getting hopper gun from Harbor Freight Joe reccomended.
Thats all for now but I'm sure I will have more questions. I have learned all this from studying you guys posts. I really appreciate your help. Thanks

[joe]

Woopee for you Romondo:

I have no idea what the materials you have described are all about. And it would be helpful if you posted a drawing of the proposed sign. Is this a double sided?

It would also be helpful if we knew what kind of shop equipment you presently have and are you comfortable with standard construction techniques.

Joe Crumley

[sigmagraphics]

Woopee for you Romondo:

I have no idea what the materials you have described are all about. And it would be helpful if you posted a drawing of the proposed sign. Is this a double sided?

It would also be helpful if we knew what kind of shop equipment you presently have and are you comfortable with standard construction techniques.

Joe Crumley

The material is Pink Foam. Its sold at HD for $31 for 2 inch.
I have attached a picture of design I did. I'm still doing a lil tweaking
but it will give good idea of what I am doing. This will be a single sided
sign.

As far as equipment, I have 24" vinyl cutter, 60 watt laser. I can cut full size sheets on my cnc. I have very good painter and airbrush artist on staff.
I use Corel Draw to design and Vcarve for tooling. My shop has plenty construction tools. I will be purchasing bow foam cutter within next week to shape foam to do basic cuts.

So, I can do most construction techniques. Also, the shield on the sign will be PVC. Thanks
15246
15250

[joe]

R.

This is the way I go about it. I make a hard coat of board for all surfaces. This way a hard thrown baseball won't have much if any effect.

Incidently this is a $4000. project. First time you make one of these it will devour time.

http://i38.photobucket.com/albums/e115/jcrumley1/IMG_1805.jpg

Once again, there is NO hard surface material that can be painted on that is truly hard. I like MDO best. HDU is way too expensive and it doesn't like nuts, bolts, nails or screws.Your whole sign can be made of hardboard except for it's foam center.

Joe Crumley

[sigmagraphics]

Thanks Joe,
What would suggest for filling surface gaps between mdo and foam so that I can sand the pieces evenly? I read one of you old post about applying applying automotive I plan on applying the ultracrete after everything is sanded and surfaced evenly. I was going to use the West System 2 part epoxy to glue the pieces together. Lastly, do you use strips of MDO to cover the top. Doing the front, sides and base are no problem. The challenge seems to be constructing the top to cover the exposed foam. Thanks.

[joe]

I used Dibond on rounded pieces. I have a mill to put it through to give it a curve. It's necessary to have an oversized piece so you can take a bit with roller bearing to trim it smooth front and back.

You can take the epoxy and add sanding dust to make a thick, peanut butter thick, filler. Be careful and trim it up before it hardens. I've also used Durhams Rock Hard Putty. It's much more friendly.

Good luck.

Joe