Once the sign face was finished, Dan pulled it off the router and cut six more layers of Precision Board high density urethane (HDU) which he would laminate up to form a sign more than seven inches thick. The three middle layers would encase a welded steel frame. He used the cut Precision Board HDU as a jig to hold the 3" x 3" square tubing in place as he tacked it up. A piece of 1" square tubing with a 5/8" nut was welded up on top. An eye bolt would thread in this to be used for transport and lifting the sign into place. Once everything was tacked he pulled the frame out and welded everything nice and secure.
Dan then laminated up three layers of the cut Precision Board HDU and slid it over the welded frame. He then added the other four layers (including the front) one at a time.
We used multiple layers of 1" thick 30 lbs. Precision Board HDU because we happened to have a lot of that in stock but we could have used thicker sheets. Once the sign is finished, the laminations won't show. In the past we have made the signs hollow, but we have found the extra labor outweighs any savings in materials. Additionally, we have had some troubles with de-lamination because the joints are small in relation to the size of the sign — properly glued HDU should never delaminate! The sign face needs to be this thick for the “stone” to look proper.
We have found building a sign over a heavy welded steel frame serves a number of purposes. The sign is mounted securely and is very stable while we work on it. Thus, we can work on and paint all sides of the sign without difficulty. With the removable eye bolt on the top of the sign we can lift the sign up and then back our trailer under it to load and deliver it. The eye bolt also served as a top tie down point without any risk of damage to the sign. The sign will be mounted to a simple concrete footing/slab. This means the sign installs in minutes with only four holes to drill and four anchor bolts to set. Leveling is also easily accomplished. Best of all the sturdy framework is hidden inside the sign, meaning there is no chance of rust showing. Lastly, the sign has no chance of ever warping!
Next we will weld up the bottom framework for the rock work and begin adding the finishing touches to the sign.