The files for the excavator sign were routed in three stages. First Dan cut the reliefs using a 3/8" ball nose bit to rough out the shapes. A final pass was done with a 1/8" bit and an 80% overlap. Then he did a second cut file using a 3/8" milling tool to cut the rest of the pieces out.
The pile of pieces resembled a 3D jigsaw puzzle but it won't take long to sort the out.
First, Dan welded up some 3" square tubing which would form the sign’s stand. The top of the 'T' would be glued into the sign for strength! Dan used Coastal Enterprises PB Bond-240 glue to do the task. He also used some coarse threaded screws instead of clamps to hold everything secure while things cured.
Then Dan started in on the pieces of the excavator. He hollowed out both sides of the excavator’s arms to fit in a piece of 3/8" steel — which he had bent to shape. Once he had two sides of the arms glued, Dan added the other layers.
As usual he couldn't resist mocking it up to see how it would look...
This morning everything was good and dry. Dan cleaned up the glue lines with his die grinder and started in on the assembly. The sides of the 'gravel pile' were cut into shape with the die grinder. Dan wanted the excavator to really sit precariously on the top and to give it a cartoon flare he tipped the tracks outward at a jaunty angle, then drilled and inserted some 1/4" steel rods to hold them in place. It was all glued together with some quick drying epoxy.
Next, Dan cut a piece of 1" thick Precision Board HDU on the bandsaw and used belt sander to finalize the angle cuts he needed. Then he glued it all up. When the epoxy had set Dan broke out his big 5/8" drill and drilled a hole through the track frame and into the sign base. A nine inch long by 5/8" steel rod was glued in and then a similar hole was drilled into the tractor body. He will hide the rod with some small rocks when he starts the sculpture. The long steel rod will make the sign much stronger — high density urethane (HDU) does not have a lot of structural strength.
Dan fitted the excavator’s body on top for a quick picture but he won't glue it until the painting is done.
Once the last of the pieces for the excavator sign are off the CNC router they can be fastened to the base.
The hydraulic cylinders and hoses have yet to be fashioned and the pile of gravel will yet get some detail but the sign is coming along nicely. It's hand work from here on in.