Sign Invitational Challenge 2017 - Part one

With Christmas fast approaching and some quiet days scheduled between Christmas and New Years it was time to work up my ideas for the next Sign Invitational challenge. It is my usual habit to work on personal creative projects in this period.

The design parameters for the competition are similar to last year although there are a few changes. The build envelope is still 24" x 24" x 72" tall. Movement and special effects are allowed but must be triggered by the viewers. The theme is 'Sign Magic'.

That left a lot of opportunity to be creative. As I thought about my piece this year many inspirations came to mind.

I love trains and have wanted to build a dimensional piece for some time. I decided to have a sign painter working on a bill board with the train (and trestle) bursting off the canvas beside him, showing the magic of a good illustration. The base of the display will be chiseled out as defined by the shape of the landscape. We will also cut some mineshaft into the rock work to add some interest on the plain cut step bottom portion.

As always I have a few surprises in store and they will be revealed as I get into the build.  Here's the concept art which will serve as a basis for the construct...

Final work on Trinidad train

We moved the Trinidad pirate train back into the shop one last time today. I finally had the measurements for the cab bulkhead. I did the layout in EnRoute and then sent the files off to the MultiCam plasma cutter to do the cutting.

While the machine was doing it's work we built new pallets for the train pieces and bolted the components to these frames. This will ensure secure shipping on their way to California so they can then be mated to the operational chassis.

We then fit and welded the 10 gauge sheet metal into place for the engine bulkhead. Gauge panels will be fastened to this sturdy framework. We only have a little sculpting to finish off this project.

We can hardly wait to see all of this detail driving down the tracks!

Back in the shop

After two hectic weeks on job sites far from home it is good to be back in the shop! While I was gone Peter and the crew have been very busy. The first 53 foot semi load of arches, beams and posts are ready to send on their way right after New Years. The shop is plugged full with more pieces in progress.

We are also keeping the plasma cutter and router busy churning out components for new pieces.

It isn't often we do production cutting on our MultiCam but when it needs to be done the machine sure takes the hard work out of the process. The machine will cut all night to produce twelve shields from 1.5" thick 30 lb Precision Board for the bowling archways. Two more batches will follow in coming days. Peter made three different woodgrain patterns on the arches and then nested the files before setting the machine in motion.

We cut one shield as a test before we began in earnest. That is already in the painting process.

Black eye candy

Back in April I wrote a blog post about plasma cutting ten tons of skulls. We tossed them into the last shipment of shipping containers. On Sunday we fished two of the plasma cut pieces from one of the bins and delivered it to a local welding shop. They welded them into the test fence panels which were delivered and welded into place today. The owner and I inspected the result and declared them finished. The welder then backed his truck to the shipping container and we fished our sixty more of the plasma cut logos. Soon the park will be a whole lot spiffier and more secure.

Looking to next year at IAAPA

With a successful International Association of Amusement Parks and Attractions (IAAPA) EXPO now behind us we are beginning to dream up concepts for next year's show. Our idea to build a one piece display which set up (and take down) in mere minutes worked exceptionally well. We'll build on that concept next year. We are seriously considering taking a twenty foot booth next year, doubling our space. But to keep costs in check we want to pack that doubling of our display into the same compact shipping unit - which has to measure ten feet long by seven and a half feet wide by eight feet tall. That's a challenge!

I began the design working in EnRoute. This allowed me to work accurately and accurately in scale. It also allowed me to tweak the design quickly so all of the pieces fit together. The view from above was of a mini stage with the walls hinged at the corners to fit together perfectly.

Then the walls are unfolded the booth will measure twenty feet wide by ten feet deep. A 'floating' high-tech motor cycle will act as a photo opportunity. We will happily take pictures of our prospects and send them to them afterwards when we follow up on their visit. The motor-cycle will come out from the raised platform on a sliding mechanism and slide back to allow shipping.

Once I had a workable plan it was time to do up the concept art. The top portion of the display will fold down into the canopy for shipping. This folding mechanism will have a hydraulic assist to make the setup easy. This is going to be a whole lot of fun!

Lucky horseshoe sign

The latest project is a fun one. Once again it will involve a number of disciplines and materials. The post is to be made of structural steel surrounded by hand sculpted Fibreglass Reinforced Concrete. The horseshoe and sign board will be routed from 30 lb Precision board (with a welded steel core) and the horse will be hand done using sculpting epoxy. 

I used the hand drawing as a template to create the vectors I needed to create the routing files. This project is fairly simple. I then duplicated and combined the vectors to create the middle section of the sign. A square tubing frame will be fit and welded up into the center to add some structural strength.

I started with the sign board. A simple flat relief was created as a first step. I made it 1.2" tall.

I then used a modifier file (from the new Woodgrain Texture Collection) Keeping in mind that black does nothing, white will raise the relief by the amount entered and greys do something in-between depending on their value we know that this bitmap file will effectively twist or warp the relief by 0.4" over it's length and width.

Next up was the woodgrain. Before this step I created a copy of the vectors and flipped them for the back side of the sign.  I removed the lettering from this sign. Once more I was using a bitmap file from the new woodgrain collection. For the front side I drew a rectangle around the board for the purpose of modifying the relief. I did not want the woodgrain to go through the lettering and by selecting the relief, the lettering border and the rectangle the texture is applied to the board but not the lettering.

On the reverse side there was no lettering and so the woodgrain bitmap texture was applied to the entire board.

I then selected the relief and that same lettering border and modified the relief by raising the lettering border. It followed the warp of the board.

I then selected the lettering and the base relief (the board) and added the lettering using the dome tool.

The horse shoe was created in a number of steps.  I first created a flat relief using the horse shoe shape. Then the toe piece and heel nubs were created and taller reliefs. These were then combined with the base relief. The long holes which hide the heads of the nails were subtracted from the horseshoe relief on the front side of the sign only.

I then used the subtract from command to cut the nail holes into the shoe by 0.2" This was done on both sides of the sign.

I then combined the reliefs to finish the files. They were then ready for tool pathing and sending off to the MultiCam.

Thinking ahead

Before the International Association of Amusement Parks and Attractions EXPO had finished we were already talking about next year's show and what our booth might look like. At this show, like every show entry we had previously done we were reminded that people ask about what we have on display. They can't imagine what else you might be capable of.

We had packed this year's display chock full of signs, design art and pictures of finished projects. Our videos were playing on the television and we had slide shows handy on our iPads. It worked well. But not year we want to build a booth that showcases our larger work along with our ability to tell a good story. We will most likely also include a drawing table with me perched there doing some concept drawing. We will also spell out (with signs) that we do concept design, and building of mini golfs, adventure parks and themed restaurants.

While we crammed a whole lot into ten by ten feet this year we are thinking a twenty foot booth next year would allow us to operate a lot more comfortably - especially when things get busy. As far as theme, well, it has to be over the top.

Before we began design we sat down with the organizers of the show and talked about rules regarding height and signage. They do not restrict height for showing our product. We just can't put any of our advertising up there. No problem!

After much discussion we decided on a space - mechanical - tech theme. We wanted it to be colourful but well worn and aged. We also wanted a photo opportunity in the booth - hence the flying motorcycle. Who could possibly resist? We want to create a truly memorable experience (with pictures) for all who stopped in. We will offer to take their picture and with a badge scan send it to them by email.

The entire twenty foot booth will assemble easily and quickly, folding out and tipping up with little extra assembly. It will condense down to form a single ten foot by eight foot self enclosed pallet for ease of shipping.

This is going to be fun!