Pub sign step by step – part four

The sign was routed in two pieces for each side. I had mistakenly not reversed the toad stool and so the two halves would not match up. This wasn’t a big deal however for they would be extensively reworked by hand when I sculpted them later.

I welded up a quick frame with 5/8″ round steel bar. This was then placed on the back of one of the halves and an outline traced out with a pencil

I then used my air powered die grinder to create a half could hollow into which I would glue the welded frame. Once I had the first half done I put in the frame added the other side of the sign and carefully flipped it over. I then repeated the process.


Once everything fit properly I spread some PB Bond 240 glue (Coastal Enterprises) This is a one part glue activated by a spritz of water.

I then used some coarse wood screws to fasten the two sides together. I added the two school top pieces using the same glue.


I then ran some 1″ pipe through our bender to form the correct radius I needed.


I cut the fancy bracket from some 1/4″ plate on the MultiCam plasma cutter.

All of this was welded up and then bolted on to a temporary stand for finishing.

Now it is time for the fun part – hand sculpting and panting. Stay tuned…

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Dan Sawatzky

Dan Sawatzky is best described as a creative force in the sign industry. He and his wife Janis are owners of Sawatzky’s Imagination Corporation – a small family company that specializes in the design and creation of dimensional theme signs and environments. They tackle projects of any size from small signs to entire theme parks. Their work has garnered numerous international awards and Dan’s articles appear frequently in the sign trade publications. Dan and his crew also host Sign Magic and Sculpting Workshops in their studio a number of times each year with attendees coming from around the world. For more information please visit www.imaginationcorporation.com

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