The sign is to be built in five layers. The front and back (cut from 2" thick 30 lb Precision Board. The three middle layers would be cut from 1/2" thick Precision Board. The gears would then be cut separate which would allow all of the gears to read as separate and look more believable. The square lines are for a cutout, into which I will insert a welded step frame.
I'll be routing the sign tomorrow and then I'll post the assembly pictures in the next couple of days.