I built the 3D files using EnRoute Pro software. To save routing time I decided to built each side of the sign in two layers of 1" thick 30 lb Precision Board. This would make the sign almost 4" thick when it was all glued together. The compass points layer was routed using only a 3/8" bit with a 90% overlap. This made the file run pretty quick.
While that file ran I created the second file. Because of the fine lettering I would use a small 1/8" ball nose bit to route this piece. Because it had a much smaller area than the first piece a small bit didn't take too long to route.
While the MultiCam was busy I cut the steel and welded up a stand, pole, and an interior frame around which I would laminate the pieces.
Stay tuned for the next installment...