We transferred the design onto a transparency and then projected it onto the boards for tracing. With the outline in place, I cut the boards using a jigsaw to get the proper shape to the blank.

The design is projected on the face of the sign and then marked off. Here, Linda Roederer adjusts markings before final cutting to bring the blank into shape.

At this point, the blank was sanded using 120-grit paper with the belt sander and then finished-sanded using 220-grit paper and an orbital palm sander. Next, I primed the blank using Chromatic fast-dry blockout and applied two coats of Chromatic oil-based paint. The pain coats, allowed to dry for 24 hours, were sanded with #00 steel wool between applications.

The face is sanded first with a belt snder using 120-grit paper. Here, Paul uses an orbital palm sander for a second sanding with 220-grit paper.

Next, the sign is primed using Chromatic dast-dry blockout. After this, two coats of oil-based paint will be applied.

Blasting
Now the sign was ready for stencil and blasting. We cut the lettering on a Roland CAMM I 24-in. plotter using Hartco 4255 stencil. While I regularly use Hartco stencil, I thought it was particularly important to make sure I used it on this job!

Here Linda applies the main stencil to the sign

After applying the stencil, I covered the edges of the sign with duct tape to protect them.
The blast was accomplished using440-grit silica sand at 95 PSI.
A word about ventilation and respiration are in order here. Anyone who is serious about sandblasting will hammer on these points, but they always bear repeating. It is critically important to use good respirators and ventilation equipment when sandblasting. Paint fumes and other solvent vapors pose enough of a risk, but airborne particulates present a serious health hazard. Breathing silica dust is extremely dangerous.