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Making a Zombie Sign

Discussion in 'Portfolio Board' started by cnc602, Jan 13, 2016.

  1. cnc602

    cnc602 Member

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    Nov 5, 2009
    Making a Zombie Theme Sign for work.
    It will have Dibond Letters on standoffs.
    Inlayed carbon fiber letters and a center
    focus point using Dibond, Acrylic, Carbon Fiber and red vinyl on plastic.
    Sign will be 6" x 22"
    Will be using a 2550 CNC Router to make the sign.
    See image for more detail.
     

    Attached Files:

  2. Andy D

    Andy D Very Active Member

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    I LIKE IT!
    I am a zombie fiend!
    Please post pictures of the final sign.
     
  3. Jillbeans

    Jillbeans Major Contributor

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    It would look a million times better if you reduced the size of everything to give more breathing room around the edges.
    Love....Jill
     
  4. Billct2

    Billct2 Major Contributor

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    or make it 24"
     
  5. kheebl

    kheebl Member

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    I Love it, I am a zombie fan!
     
  6. cnc602

    cnc602 Member

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    Nov 5, 2009
    Ugh You guys are right, if I reduced the size of everything or make the wood back piece bigger it would frame it and make it look a lot better!
    Unfortunately I've already cut the back piece and some of the letters. Plus I have to get this done for a tradeshow coming up soon the Shot Show.
    However, will probably cut a bigger back piece after the show, would be easy since it's just wood and I'm using a CNC Router.
     
  7. cnc602

    cnc602 Member

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    Nov 5, 2009
    Here are the photos of the wooden back piece.

    Photo 1- Holes drilled for standoffs
    [​IMG]

    Photo 2- Routed out the shape of the wood back piece
    [​IMG]
    [​IMG]

    Photo 3 - Routed out the circle for the Zombie Scope
    [​IMG]

    Photo 4 - Engraved the letters for the Carbon Fiber inlay letters
    [​IMG]

    Photo 5 - Finished wood back piece.
    [​IMG]
     

    Attached Files:

    Last edited: Jan 14, 2016
  8. cnc602

    cnc602 Member

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    Nov 5, 2009
    Ok got some photos of the Dibond letters being cut on the CNC router.
    Some people might know what Dibond is for those who don't know what Dibond is, it's a brand name
    of a material consisting of a solid piece of polyethylene (plastic) sandwiched between
    two sheets of aluminum. This make for a rigid aluminum like material but lighter. (I added links for more info)

    Making the countersinks for the standoff screws
    [​IMG]

    Close up of the tool and the countersink hole
    [​IMG]

    Here are the cut Dibond letters. Vacuum boot for removing dust & debris, removed for a better photo
    [​IMG]

    Close up of the routing tool used
    [​IMG]

    Letters routed out still in the Dibond
    [​IMG]

    Here are the letters again cleaned up a little
    [​IMG]




     

    Attached Files:

  9. Billct2

    Billct2 Major Contributor

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    Are you going to have an industrial look with big visible hardware for the standoffs?
     
  10. cnc602

    cnc602 Member

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    Nov 5, 2009
    Yup the screws will be visible, thinking it matches the theme.
    Thoughts? Suggestions? :)
    Maybe not for this sign but the next build.
     
  11. Billct2

    Billct2 Major Contributor

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    I like the idea.
     
  12. cnc602

    cnc602 Member

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    Nov 5, 2009
    Ok got to work on the letter "O" in the word Zombie.
    We are going to make it look like rifle scope with cross hairs.
    Were using various materials to give it a dimensional look.

    Layer 1 is a Zombie graphic made from sticker vinyl on plastic.
    We used Print-To-Cut and an engraving head, how it works is a camera sees the registration marks (dots) on the application and uses it to align the cut to the graphic.
    [​IMG]

    Layer 2 is a routed out piece of half inch acrylic, were using routing head for this.
    It's a little bit of a mess because we removed the dust collection boot from the CNC router to show the routed area for a video I'm putting together.
    [​IMG][​IMG]

    Layer 3 is the Crosshairs engraved out of Carbon-Fiber.
    Please note, if your going to work with Carbon Fiber, use gloves and a mask.
    You don't want to inhale or get the fibers on your skin.
    [​IMG]

    We also did the Carbon-Fiber letters that are going to be inlayed into the wood back piece.
    [​IMG][​IMG]

    4th layer is a part that we added and was not in the original design, this acrylic part will help hold down layers 1, 2, & 3.
    [​IMG]

    The 5th layer is the Dibond letter "O" that we routed out earlier.
    Here are a photos of all the pieces.
    [​IMG]

    Here is the Zombie Scope put together.
    [​IMG]

    This Zombie Sign is practically done. I'll get photos of it put together either today or tomorrow.
     

    Attached Files:

  13. ExecuPrintGS

    ExecuPrintGS Member

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    Awesome project.
    How thick is that carbon you cut? Ive always wondered if we could cut carbon on our CNC (any advice on bit size and speed would be awesome, and where you got the carbon sheets) :rock-n-roll:
     
  14. Jacob Singer

    Jacob Singer Member

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    I'll second this question, we use a Vision 1624 for all our ADA and engraving, but I'm always looking to expand our boundaries.
     
  15. GypsyGraphics

    GypsyGraphics Major Contributor

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    Mar 19, 2009
    great sign (including intentional visible hardware)

    what a great thread too, so cool to see photos of all the steps your taking to create the dimension!

    been wanting a Visons for quite some time, hope to see the video you mentioned.
     
  16. cnc602

    cnc602 Member

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    Nov 5, 2009
    Hello the sign is done! We took it too a trade show.
    I'll be posting the final pics next week.

    To answer the questions
    I used a multipurpose hard plastic cutting end mill from Onsrud model 65-000.
    I ran the spindle at 12,000 and at the RPM the manufacturer recommends a feed rate of .4-.8 ips.
    The carbon fiber sheets came from a past project but you can find them on Amazon.

    If your going to work with Carbon Fiber, don't forget to use a mask and gloves. :)
     
  17. cnc602

    cnc602 Member

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    Nov 5, 2009
    Here are photos of the finished Zombie Sign.

    All the parts of the Zombie Sign ready to assemble.
    You'll notice the Dibond letters are covered in red sticker vinyl.
    We had pre assembled the sign and felt it was very lack luster.
    It did not POP like we wanted.
    I'll post a photo of the sign with black letters, you'll see what I mean.
    [​IMG]

    Here is the finished Zombie Sign
    [​IMG]
    [​IMG]
    [​IMG]

    Here it is with black Dibond letters
    [​IMG]

    What do you folks think? Was the color change a good idea or should we have stayed with black.
    We also went back and forth on the the letter "O" being red or black.
    With kept it black to give it more contrast to the rest of the letters being the focal point.

    Were also thinking of adding led lights behind the letters to accentuate the stand-offs and give it more pop.

    Thoughts?
     

    Attached Files:

  18. J Hill Designs

    J Hill Designs Major Contributor

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    looks pretty killer. I dig the red.
     
  19. ExecuPrintGS

    ExecuPrintGS Member

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    Turned out great, though my OCD doesn't like that the M mounts different from all the other letters (screws in the center not top and bottom).
     
  20. Marlene

    Marlene Major Contributor

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    love it! love how you used the "O" as a target with a zomibe. love seeing the hardware. the only thing that bothers me is the natural wood. I would have loved to see it a faux rusted metal or something else more industrial as the rest of it has that feel
     
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