In response to the many requests for information about how I do the routing on the signs, I will give a step by step below.
When I get an order request the first thing I do is pick out or make a sign blank in the approximate size the customer requested, then I go to my computer. I have a program on on my computer that will print out banners, I use Print Shop. I can choose many styles of lettering and adjust the letters to any size that I need to fit on my board. When I get everything how I think it will look best, I print the banner. I move the banner over to my board and tape it down where I want the lettering to be. I use carbon paper to transfer the letters to the board. Then with the appropriate bit in my router I sit, get comfortable and just follow the lines.
I have tried many different bits and found myself always going back to my 60 degree v-groove bit for most jobs, adjusting the depth for larger or smaller jobs. I also use a 1/4 inch straight bit or a 1/8th inch straight bit for cleaning up the inside of the bigger pictures or letters. As for the router, I use a 1 1/2 horse, regular size router. When I paint the lettering and designs I just use regular indoor-outdoor craft paint and I am not really careful about staying in the lines. When the paint dries I just sand the piece again and clean up my mess. I like to coat it with 2 coats of polyurathane, add the screw eyes and the chain to hang it and it is done. Oh, I be sure and get a picture of it before it goes to it’s new home so I don’t forget what I did. !