Lettering is ½-in. PVC board routercut on a ShopBot router [www. shopbottools.com] mounted on a 10-by-4-ft. panel of 2-in.-thick 18-lb. Precision Board HDU board that was sandblasted and hand carved.
CNC-routed and hand-carved double-sided 3-by-4-ft. 18-lb. HDU panel with an internal square tube frame for mounting
Fabricated by HBS Copper with installation by Brushstroke Signs
CNC-routed 32-by-38-in. panel of 3½-in. 18-lb. HDU panel with an internal square tube frame for mounting
Rob was the project leader for this 14-by-18-ft. mural painted for the 2009 Pontiac, Illinois, Walldog meet.
Letters are aluminum composite material cut on the CNC router, with holes drilled in back for stud mounting on the black and white aluminum composite panels. The main background panels were ¼-in. aluminum swirl grinded and painted with House of Kolor Kandy Kolor red and urethane clear.
32-by-14-ft. mural painted with NovaColor Artists’ Acrylic paints. “This mural is inside our historic Coca-Cola bottling plant,” Rob says.
Router-cut PVC letters on 10-by-3-ft. layered PVC panels, finished with NovaColor Artists’ Acrylic Paints
Digital print on 18-by-24-in. double-sided 6mm aluminum composite panel
Digital print on 6-by-4-ft. single-sided 6mm aluminum composite panel mounted on a PVC post and rail kit
Sandblasted and hand-carved 84-by-14-in. panel of 18-lb. HDU board; letters are finished with 23K gold leaf
CNC-routed 36-by-24-by-2-in. PVC panel with pocket cuts for the logo and the lettering, and a welded internal frame for mounting
Letters are PVC board on a 10-by-4-ft. layered PVC panel. It’s finished with Sherwin Williams All Surface Enamel and Modern Masters metal effects Copper/Green Patina finish.
Sandblasted and hand-carved 7-by-3-ft. panel of 2-in.-thick 18-lb. HDU board finished with 1 Shot lettering enamels; SIGNS is finished with 23K gold leaf.
CNC-routed 24-in.-diameter white oak panel applied to 6mm ACM backing panel over an internal frame of welded square tubing
12-by-12-ft. logo painted on a brick wall with NovaColor Artists’ Acrylics
Paducah was router-cut and finished with 23K gold leaf, then applied to the sandblasted 8-by4-ft. panel of 3-in.-thick 18-lb. HDU board.

Rob Estes

By SignCraft Magazine

Posted on Saturday, December 29th, 2018

Shop name:
Brushstroke Signs

Shop size: 2400 sq. ft.

Age: 49

Graphics equipment:
MacBook Pro
Graphtec plotter
ShopBot 4×8 router

On Facebook as Brushstroke Signs
Paducah, Kentucky, sits at the juncture of the Ohio and Tennessee Rivers, about 40 miles before the Ohio empties into the Mississippi River. It’s a growing historic river town of about 25,000 with a total of 65,000 including the surrounding county. It’s also home to secondgeneration sign maker Rob Estes.

Well-known for his mural and wall work, Rob turns out a variety of custom sign work from his one-man shop. Both his father and uncle were in the sign business, and he worked in his dad’s shop from 1984 until enlisting in the US Navy in 1989. He then opened Brushstroke Signs in 1995. SignCraft spoke with him between finishing up a large engraved plaque and planning a wall lettering project—and hoping the mid-November weather would cooperate.

Bread, butter and 3D Most of my work is what I’d call breadand-butter—digitallyprinted and some routine vinyl signs. I also get a decent mix of layered dimensional work that I do with the CNC router and hand carving. Before I bought the CNC router, most of my dimensional work was sandblasted. I don’t do as much blasting as I used to, but mix the two when the job calls for it.

Overall, the dimensional work is my favorite. Seeing a project start as a onedimensional sketch and turning it in to a piece of advertising sign art for the customer is very rewarding. I enjoy all of the aspects of the process. My dad used to tell me that some jobs would call us to be an engineer, electrician, carpenter and a sign painter. In his shop we did everything from hand lettered vehicles to electric signs but I find that it is best to limit myself to certain types of work. I’ve created my own niche with the custom carved, routed, hand painted walls and signs.

Working solo Since I opened, I’ve worked alone for the most part. I have had a couple of part time employees on an as-needed basis over the years but never hired anyone full time. I’ve become comfortable wearing so many hats of the business that it makes it tough to give up the hands-on part of the workload. There have been times that it has crossed my mind to hire someone but I have always decided not to.

Taking advantage of outsourcing Most of my customers are small businesses, and I handle those jobs in the shop. One of my larger customers is a local hospital that orders several laser engraved donor plaques throughout the year. I sub out this type of work to GeminiPlaques.com. I also outsource my digital printing too. I’ve had a couple of printers, but have found that in my situation it makes more sense for me to outsource it to someone like Signs365.com. This way I don’t have to stock all the different materials and laminates or worry about maintenance issues. I can an order before 8AM and I’ll have it the following day.

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