Create layout: 20 minutes I did the layout in Gerber Omega software. Later I would send the text to the plotter to cut the sandblast stencil.
Cut blank to shape: 25 minutes I used a western red cedar sign blank from Allwood SignBlanks, and cut it to shape with a scroll saw, then sanded the edges.
Cut border and graphic masks: 30 minutes I taped off the borders and hand cut them, then made a pounce pattern of the graphic and cut it.
Cut and apply text masks: 35 minutes It took only a few minutes for the plotter to cut the stencil for the script and numerals, then I applied it.
Sandblast the blank: 35 minutes That’s the approximate setup and blasting time. I take my signs to a nearby sandblaster and let him handle it.
Prime background, remove stencil: 25 minutes Before removing the stencil, I sprayed the background with Zinsser Bulls-eye 123 primer to minimize bleeding.
Rout bevelled edge: 10 minutes Routing a quick bevel on the edge adds a nice finished look to the panel.
Painting: 40 minutes I sprayed thesign with light blue exterior latex. When dry, I rolled the blue latex on the letters and borders.
Paint graphic: 40 minutes I hand painted the graphic with 1 Shot enamels.

What’s it cost to produce this 23-by-32-in. sandblasted sign?

By David Showalter

Posted on Thursday, December 27th, 2018

Allwood western red cedar sign blank: $130
Sandblast mask: $45
Paint: $30
Total materials: $205

Design: 20 minutes
Cut panel to shape: 25 minutes
Apply stencil masks: 65 minutes
Sandblast: 35 minutes
Rout edge: 10 minutes
Painting: 80 minutes
Total time: about 4 hours
I’ve done quite a few signs for private residences over the years. It started with a few signs for cottages at the lake and kept growing. Sometimes they come as the result of doing other sign work for someone. I have several signs like this in my display area and that has helped sell more of them. Some customers never think of getting a sign like that until they see that you do them.

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David Showalter

David Showalter's shop, David Design, is in Bryan, Ohio.