Fox Head Barrel

As part of the design process for our Fox & Hounds Pub project, we created a few samples. These pieces also helped to ensure the contractor and trades were on the same page and knew what to expect from us. Our first sample was a fox medallion.

My father created the vectors for the barrel in EnRoute and then used the jigsaw tool (pictured below) to create the staves of the barrel.

He created the outer ring and the barrel top first. (As usual) he used the render button to double check his work.

Then dad selected the outer staves of the barrel and built each one separately (with slight variations in height). As usual, he created each one as a separate relief.

Then he imported the sandblasted wood grain bitmap (from our Texture Magic: Classic Collection).

Since bitmaps can't be rotated inside of EnRoute, dad selected everything else and rotated the reliefs to apply the textures to the barrel staves. At this point everything was merged together for form one relief.

To create the fox, dad used a stock STL file. He resized and positioned it before merging it to the barrel top he had created previously.

And just like that it, was ready to tool path and send off to the CNC router.

G Street - Part 2

G Street Sign Series: Part 1

As with most types of signs, hanging signs need some interior structure to make sure they stay securely in place. Over their lifetime, signs are subjected to high winds and endless gravity. And of course, there is also the occasional “macho dude” who sees something like a hanging sign and suddenly has to prove how tough he is by jumping up and doing a few chin-ups. We always want to be sure that our signs will withstand the vagaries of weather and weirdos and an internal welded steel frame is our insurance policy.

In the G Street sign’s case, the frame was made from 5/8" solid steel bar. This level of structure is probably overkill but better safe than sorry — after all, it is impossible to make something too strong!

The sign will be suspended by the cast steel eye bolts (which are rated for 5000 pounds each - more than enough!). Once the frame was welded we laid it on the (interior) back of the sign to marked out where it would go. Then, using the die grinder we cut in a 1/2" deep slot not the sign.

We repeated this step on the second side as well, test fitting dry to make sure everything lined up tight.

Then we spread on the Coastal Enterprises PB Bond-240 glue which is formulated for Precision Board HDU. We misted the Precision Board with water to activate the glue and clamped it up tight to dry.

Once the steel is firmly glued inside the sign it was time to glue on the rest of the sign’s detail.

Below you can see the results of our efforts — just waiting for paint.

See you next week!

G Street - Part 1

Jack Niemann's Black Forest Steakhouse needed a second sign for the handicap accessible entrance. Obviously, Jack wanted the sign for the “G Street” entrance be be done in the same style as the first sign. My father’s first step was to create the sign’s vectors in Illustrator - a vector program he is very comfortable with.

Then he imported the vector file into PhotoShop and quickly created this illustration with his digital pen and drawing pad to show Jack what he had in mind — he gave his instant approval.

With Jack’s approval in hand dad imported the vectors into EnRoute and began the task of building the routing file.

He could have used the “sweep two rails” tool to build the crown moulding, but opted to build each element separately and then merge them together at the end for maximum flexibility. Since the vectors were separated into groups, he used the “jigsaw” tool to cut out the shapes and then merged them together.

Then dad used the “bevel relief” tool to create a relief twice as wide as he needed before he merged (merge highest) a zero height relief (of the correct shape) to it to create the final shape he needed.

The top and bottom flat portions of the crown were done in a similar fashion using the “jigsaw” tool.

Then he made the egg shaped reliefs and merged highest to the crown molding.

Once the balance of the reliefs were created, dad merged them together to form the sign. He duplicated and flipped one of the reliefs to make sure the two halves matched perfectly. before adding the G to each side as a beveled letter.

He divided the sign into six pieces to be routed from 2" thick 30 lbs. Precision Board HDU.

Here it is on the CNC table, being routed.

See you next week for Part 2 of the G Street sign series!