
We’re going to use a Dremel router to make a sign with recessed lettering. I suggest barnwood because of the contrast between the weathered surface texture and ‘fresh cut’ letters. I also have enhanced the letters by burning (pyrography) the edges of the letters for increased readability. Of course you can scale up to larger routers if you chose.
Stock: Barnwood 2”x10”x24” Suggested material and dimensions
Safety: Goggles, Facemask, Gloves
Tools: Small straight blade knife: Stop-Cut / Outline Dremel (model 300) Flexshaft optional Plunge Router attachment #335 Dremel Bits: Roughout Routing 1/8” #650 3/16” #352 1/4” #654 Smooth Routing 5/16” #115 1/4” #116 1/8” #194 Air Compressor with nozzle for dust removal and increased visibility while cutting
PROCESS: Design Print Overlay Trace Mask Optional to protect rustic surface
Knife Cut – Stop Cut
Hog out
Clean Edge
Clean Body using high speed cutting bits
Sanding Optional if bits leave burn marks or smoother surface is desired
Pyrographic enhancement
Let me know if your interested in participating and if there are any specific questions to be answered prior to starting in January. We should be able to complete this project in 6 or 7 sessions so be prepared to quickly have results you can hang!
Happy Holidays!
Bruce aka ‘3DbME’

















13 comments so far
~Julie~
home | projects | blog
526 posts in 1205 days
#1 posted 527 days ago
I’ve done this with a router, but I’ll watch since I need to figure out how to get into small corners!
Thanks!
-- ~Julie~ followyourheartwoodworking.blogspot.ca
Brian Rickman
home | projects | blog
8 posts in 533 days
#2 posted 527 days ago
I made one sign with a Dremel. It came out OK, but not anywhere near as nice as the picture you show here. I’ll be watching with interest.
mafe
home | projects | blog
8057 posts in 1260 days
#3 posted 527 days ago
Look forward to follow.
Best thoughts,
Mads
-- Mad F, the fanatical rhykenologist and vintage architect. Democraticwoodworking.
John in SD
home | projects | blog
140 posts in 1983 days
#4 posted 527 days ago
Looking forward to this….....but can we use a trim router ?
-- Life used to be soooo much simpler!!!!
3DBMe
home | projects | blog
128 posts in 1855 days
#5 posted 527 days ago
The Dremel is suggested since this is the tool I used for this size sign. You are welcome to apply the basic concepts to your toolset and style. With larger bits you’ll obviously need larger ‘minimum radius’ at the corners therefore larger text such as with large signs. The other thing about the plunge router, big or small, is the ability to set a specific depth to plunge to where as with a fixed base you may have to enter at an angle which may/can be dangerous. Safety first.
-- http://www.brucemgil.us/
macfil20
home | projects | blog
6 posts in 672 days
#6 posted 525 days ago
Looking forward to see how to do this.
-- JP
ShopTinker
home | projects | blog
862 posts in 939 days
#7 posted 524 days ago
I’m looking forward to following along. I’ve been thinking about making a sign for my sisters cabin. Great timing.
-- Dan - Valparaiso, Indiana, "A smart man changes his mind, a fool never does."
Vicki
home | projects | blog
847 posts in 1515 days
#8 posted 524 days ago
Sounds like a winner to me. I look forward to it and thanks for doing it for us.
-- Vicki on the Eastern Shore of MD
DrSawdust
home | projects | blog
303 posts in 2268 days
#9 posted 509 days ago
Very interested in doing this. Looking forward to the new class in the new year.
-- Making sawdust is what I do best
JoeyG
home | projects | blog
1161 posts in 796 days
#10 posted 509 days ago
I do the same type of thing with my epoxy inlays. I don’t know that I will have time to participate, but I will be following along. Your sign looks great.
-- JoeyG ~~~ http://www.facebook.com/JHGWoodWorks
Jim
home | projects | blog
92 posts in 1262 days
#11 posted 504 days ago
Count me in!
-- Artificial Intelligence is no match for Natural Stupidity….
ElmoSr
home | projects | blog
225 posts in 1197 days
#12 posted 494 days ago
i want in also , when/how do i get in line?
-- ElmoSr,Ga. Life is Hard by the Yard,,,But a Cinch by the Inch
thelt
home | projects | blog
566 posts in 1550 days
#13 posted 492 days ago
Let me know when the start date is. Love to follow along.
-- When asked what I did to make life worthwhile in my lifetime....I can respond with a great deal of pride and satisfaction, "I served a career in the United States Navy."
Have your say...