How to Route a Wood Sign

How to Route a Wood Sign by Rex Rothing

A unique gift idea

First decide which is more important; the size of the letters, or the size of the sign. Most times you can't have it both ways. If the letter size is important, then the sign board dimensions will be determined by the number of words. Or, if the sign board dimensions are important, then the letters need to be adjusted in size to fit.
Pick out a board bigger than the size you will finish with, or you can work with the exact size board you find, with a little more difficulty, depending on the number of words. Prepare this board by planing, sanding, and trimming up rough ends.
Letter or draw the sign either by hand, by stencil, or by computer assisted printout. Home-made or country style signs look good drawn freehand. Regulatory or business signs and more formal or traditional signs look good neatly stenciled, and for fancy fonts, more words, better layout, or pictures, a computer can be used. Lettering or images can be printed out and spray glued directly to the board, or lettering can be marked boldly with pencil or pen. After the routing all paper or pencil marks will be sanded off.
The easiest part is the routing. Place the board on a sturdy workbench. Either clamp it down or lay it on a piece of foam rubber carpet padding so it will not slide around. Pick out a router bit; either a round nose, V groove, or square end. The smaller sized v groove or rounded router bits are easier to plunge and cut with. Usually 1/4" or 3/8" wide and set in the router only 1/4" or 3/8" deep. Cutting too deep will cause difficulty guiding it and the wood will smoke and burn. This also occurs if the bit is dull. Buy a good carbide tipped bit and test it on some scrap pieces. A bigger plunge router will do the job with less effort than a smaller fixed one. Grab the router with both hands and keep your forearms touching the work table while you plunge or drop down on each letter, then make the cut using your wrists to guide the motion of the router. DO NOT touch the router down without firmly having your arms holding the position on the table. A router out of control is very dangerous. Follow safety proceedures!
Finish the sign however you like. You can paint the letters very sloppy and then sand or plane off the excess after it dries. Painting a background color is tricky and time consuming. It is usually better to put a clear finish on and let the wood show its beauty. You can oil regularly, varnish or polyurethane occasionally, or do nothing and let it be natural and turn gray if left outside. You may choose to shape the sign, cut it square, scallop the corners, sandbast it, or distress it with tool marks and chain whipping. With imagination you can create many designs.
Craft shows are a good venue for this craft. If you invest in the equipment; covered trailer, router, dust collector, generator, paint sprayer, vendor tent, workbench, license, permit, and fees for the show you might make a lot of money in a weekend. You need a source of free wood, a good assistant, good weather, and a good crowd plus the ability to work fast and ship later to some customers. But be prepared for some shows you will barely make your space rent.
A Gift Idea! People love their funny signs. Routed Signs make a fun gift idea for home, office, camper, boat, or shop. They can be names and addresses, awards, or just sayings. Like: SMITH 555 Main St., Best MOM!, Where's the BEACH?, or whatever you can imagine. If you need assistance with your making a routed sign, feel free to call or email us at WoodShop 102. We can provide the board, the rough cut, the finished sign, or just advice!