After two days of cutting plate and structural steel and completing a bunch of detailed epoxy sculpting on four signs to make them ready for paint, it was time to start assembling the project I’ve been looking forward to all week. This afternoon, we began the actual assembly and welding of the giant DOWNEYS letters. Since the ‘Y’ was on the welding table, we started with it. I first welded together the two halves of the back plate, added the 1” x 1” upright spacers at the corners and then welded on the front border. Because the pieces of plate were cut on our FastCut CNC plasma, everything fit perfectly and went together easily. With the front and back of the ‘Y’ perfectly aligned, forming and welding on the 16” tall sides of the letters (also plasma cut) proved to be easier than I imagined. Once the bottom was welded on, I cut four holes and slipped the structural steel into them, which was then welded to the letters. This protruding frame will hold the letters upright and secure when bolted to the on-site concrete foundation (cross members and mounting plates yet to be added). This frame will also make it easy and safe to stand the letters up and then sculpt the woodgrain faces of the letters. There is still plenty of fitting, welding and grinding remaining to be done on this letter, along with the six others, but it is always nice to get into a project never previously attempted and realize the plan we concocted is actually going to work.
Getting there
Until last week, I still hadn’t consistently produced laser art good enough to make me happy. It has been three weeks of draw, test, trash, adjust and repeat. Although I’m sure there will be no end to the testing and learning, I’ve discovered which style of line art reproduces best as a laser print. I’ve tried all kinds of wood and every laser setting possible with a wide variety of results. I’m now working on how to hand-colour the laser work, so it is pleasing to my eye. All in all, it has been a challenging but fun learning curve.
In my free time, I’ve also been out exploring the local area, gathering more photos for inspiration. In the evenings, I have begun working on new artwork that is better suited for laser etching. I found this gorgeous old tractor only three blocks from our house. Last evening, I created the line work, and first thing this morning set up the laser and got it running before I began work in the shop. The result made me smile.
Productive day!
We spent the morning with our FastCut CNC and burned through another ten 4’ x 8’ sheets, creating the remaining pieces for the giant DOWNEYS letters. Then we switched gears to start the sculpting on the three signs. Laura (first day) was in the shop to give me a hand, and she did great, grinding all the edges of the steel pieces and mixing the sculpting epoxy I needed. It was a very productive day! Stay tuned…
