Rout two sign faces and accents: 60 minutes I routed the faces on my Gerber Sabre Dimension 200. It took another 60 minutes to shape candles and ornaments by hand on a belt sander. The center globe was also cut from HDU board.
Fabricate and paint the internal steel hanger: 60 minutes I like to use a hanger that is integrated into the sign rather than hooks that go into or through the sign face. There’s much less risk of failure.
Assemble the sign: 30 minutes I glued and clamped the accents, sides, frame and faces using Gorilla polyurethane glue and a spritz of water. Once it dried, it took about 30 minutes to sand the edges smooth.
Spray with polyester resin: 45 minutes This gives the sign a hard, smooth surface. I mix the two-part resin 1-to-1 then thin with lacquer thinner to spraying consistency. I spray it on then pull over all the flat surfaces with a foam brush to eliminate the dimples.
Apply logo elements: 15 minutes I used silicone to bond the logo components to the sign.
