The "I'm Not Worthy" Project Log #1: Here's Your Sign....

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Blog entry by DIYaholic posted 09-01-2013 04:46 AM 2007 reads 0 times favorited 17 comments Add to Favorites Watch
no previous part Part 1 of The "I'm Not Worthy" Project Log series Part 2: Charged with A-Salt: I was Framed!!! »

This blog series will prevent the LJ “Project Gallery” from being infected with my less than “Fine Wood Working” projects, shop fixtures and jigs. I feel the “Project Gallery” should be preserved for true WW projects and not a showcase for the utilitarian “Down & Dirty” endeavors, TS Sleds, clamp racks, shop helpers and the like. This will also serve, at times, as a build log for these “Not Ready For Primetime” projects.

To get the ball rolling…. Warning!!! This is long winded & picture intense!!!

The boss purchased vinyl signs for two of our landscape trailer tailgates, you know the ones with expanded metal grating/mesh. With no way to affix the vinyl signs to the mesh, he recruited me (& my limited WW skills) to make elliptical backer boards, to mount onto the tailgates, that the signs will then be adhered to. Sounded like a relatively simple task that I could easily over engineer.

The Plan:
1/2” Birch Big Box ply, edgebanded and painted with gloss black marine paint, a couple of nuts, washers and bolts.

The signs were already made, so I needed two identical 32” x 16.5” ellipses.
No visible hardware through/on the sign.
Must be completed before the next millenium!!!

“Pictures are worth a thousand words”, so I’ll let the pictures do most of the talking.

I tried the “Two Nails & a String” thing, to draw the ellipse….
With double sided tape securing the two “blanks” together,
spray adhesive secured the much more accurate “Microsoft Excel” generated multi-page paper template:

After rough cutting on my Ricon 10-325 14” BS with a 1-1/2HP motor and 13” of resaw capacity, it was onto the oscilating belt sander for final shaping.

There’s a dryer in my shop….
Might as well do some ironing!!!

I really didn’t have a concrete plan, when I started this build….
Just a half baked idea. With the ellipses cut, it was now time to figure out the mounting plan….

The trailer has angle iron that needs to be contended with:

Mounting blocks were made from some scrap pine and 3/4” ply. The bolts heads were then imbedded into the ply with the threads protruding through the pine.

The mounting blocks were then attached to the sign board with glue and screws.
Pre-Assembly of the side mounts (bolts not in):

In my rush to get these to the sign shop, I didn’t get pictures of the final paint job. Which is just as well. I ended up using a brush and roller and am not happy with the outcome. I NEED to set up a spray booth, as the finish is not as smooth as I would have liked.

For better or worse, here are a few shots of the signs installed:

A “non-offensive” backside view!!!

The Dual Ellipse Team:

As I said, not really a “Gallery” worthy project, but….
I learned a few things….
Put my tools/machines in “The Lair” to good use….
Justified another “shop project” (spray booth)....
And most important….
I got to make sawdust!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procrastination a bad thing?

17 comments so far

View Moron's profile


5032 posts in 3946 days

#1 posted 09-01-2013 05:09 AM

you win

-- "Good artists borrow, great artists steal”…..Picasso

View eddie's profile


8565 posts in 2667 days

#2 posted 09-01-2013 05:27 AM

Randy they turned out great ,i like the motto on the sign ” When you look We look good ” holds true for you craftsman ship of this project you got em looking good

-- Jesus Is Alright with me

View JL7's profile


8672 posts in 3018 days

#3 posted 09-01-2013 11:46 AM

Looks like a business opportunity….....Over engineered maybe, but turned out great!

-- Jeff .... Minnesota, USA

View boxcarmarty's profile


16370 posts in 2413 days

#4 posted 09-01-2013 11:48 AM

Nice job at installing the blue tape…..

-- My mind is like lighting, one brilliant flash, then its gone.....

View JoeinGa's profile


7739 posts in 2060 days

#5 posted 09-01-2013 12:31 PM

I like that he has an iron in his shop. So when he asks the wife ”Hey Honey, did you iron my blue shirt?” … and her response is “I aint your maid. Iron it yourself!” … He has his own iron and a place to use it! LOL

-- Perform A Random Act Of Kindness Today ... Pay It Forward

View chrisstef's profile


17482 posts in 3059 days

#6 posted 09-01-2013 12:41 PM

I dig it Randy. Came out just like ya planned and that aint ever easy IMO.

-- Its not a crack, its a casting imperfection.

View theoldfart's profile


9772 posts in 2504 days

#7 posted 09-01-2013 01:13 PM

Yup, time to start a “Shop Iron of your dreams” thread. Good job, says a lot about your work ethic!

-- "With every tool obtained, there is another that is needed" DonW ( Kevin )

View whitebeast88's profile


4128 posts in 2243 days

#8 posted 09-01-2013 02:04 PM

great job,looks good!!!

-- Marty.Athens,AL

View William's profile


9950 posts in 2895 days

#9 posted 09-01-2013 02:05 PM

Good job randy.
I think spray booths are over rated unless you do work that requires a helluva lotta painting.
For me, depending on the paint being used, brush and roller allows a little thicker coats without runs or goops. For outside items, like your signs, I think this provides better protection from the elements than a super thin sprayed finish.
That’s just my opinion though. I’m sure most would disagree with that assessment.


View DIYaholic's profile


19624 posts in 2728 days

#10 posted 09-01-2013 02:47 PM

What did I win???

Thanks, for the “pat on the back”.

Your kind words are appreciated!
Kind of my thoughts also. You never know if the sign shop will ever need a similar project. That is why the finish was kinda important to me. The rolled paint was a little “bumpy” and the cheap brush left a few bristles behind (one of the many lessons learned). All of that telegraphs through to the surface. (If you look closely, at the first picture of the installed sign, you can see the bumps and a bristle below the shamrock.) I would rather spray 3-4 thin coats, that lay down smooth.

I had to use “blue” tape, as I was afraid that the green “frog tape” would hop around tooo much!!!

I do all my own ironing….
I don’t have a maid, err wife!!!

Since I do have to do the ironing, I wear sweaters during the winter to cover the wrinkles!!!

I would say that I had a concept, but no “detailed” plan. There is a reason that I don’t do “detailed” plans….
I don’t make mistakes, just changes to the design!!!

Thanks. That is my favorite iron….
I had to go out and buy it, just for this project. I only wish that I had needed a drum sander!!!

I think at 55mph, they look even better!!!

You are sooo right….
They did come out good! ;^)

Truthfully, I do agree about the protection of a thicker coat. There is also the setup & clean up time for paint guns. However, I need to setup a spray booth, so I can put my never used HF HVLP paint guns to use!!! That and there is less sanding needed between coats.

The real pain of this paint job, was the 16 hour dry time needed between coats. After 24 hours, there was still a few “soft, uncured” spots (in the corners).

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procrastination a bad thing?

View Roger Clark aka Rex's profile

Roger Clark aka Rex

6940 posts in 3487 days

#11 posted 09-01-2013 02:59 PM

Ah Randy, this project turned out great.
Making a retrofit to something already made is always a challenge, and you handled it well.
You’ll probably have thoughts of where you could make another one more easily, as most of us do.

-- Roger-R, Republic of Texas. "Always look on the Bright Side of Life" - An eyeball to eyeball confrontation with a blind person is as complete waste of Time.

View Mainiac Matt 's profile

Mainiac Matt

8160 posts in 2381 days

#12 posted 09-01-2013 05:42 PM

I like them Randy….

I hope Pegton does too

-- It’s the knowledge in your head, skill in your hands and motivation to create in you heart that makes you a woodworker. - Mainiac Matt

View DIYaholic's profile


19624 posts in 2728 days

#13 posted 09-01-2013 05:57 PM

Yes, the brain has processed many alternatives For V-2.0!!!

The boss does like them, very pleased. That’s all I can ask for!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procrastination a bad thing?

View DamnYankee's profile


3301 posts in 2615 days

#14 posted 09-02-2013 02:27 AM

Well done Randy.
If you use one of those foam rollers and some high grit paper you can get a REALLY SMOOTH surface

-- Shameless - Winner of two Stumpy Nubs Awards

View DIYaholic's profile


19624 posts in 2728 days

#15 posted 09-02-2013 07:58 PM

Thanks Rob.
I tried both a foam and a “cloth” roller. The foam roller left a bazillion air bubbles, which had to be sanded out. With either roller, I ended up sanding off more paint than I applied. For me I think, a spayer is the way to go.

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procrastination a bad thing?

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