The Art of Cedar Sign Making

The following will give an overview of the involved process in manufacturing an original “Warren Langley” sign.

The process of cedar sign production from conception to completion has been a self-taught process which has been tested and perfected over a period of 23 years. The end result is being able to provide our clients with a product designed to provide many years of service in all weather conditions and environments.

Cedar Selection

The use of western red cedar in my signs is attributed to the remarkable degree of natural weather tolerance and longevity, as well as the beautiful characteristic raised grain effect resulting from the sand carving process. Only clear, knot free, kiln or air dried cedar is selected in the form of rough cut planks.

Preparing the Blank

The cedar is planed on both surfaces and cut into strips approx. 1.5” wide x 2.25” thick. These strips are cut to length depending on the width of the sign being built. They are then planed on edge to create a perfectly flat surface in order to glue together into sign blanks. The size is usually about 10% larger than the required finished sign size. Gord McQuaid, Warren’s woodwork shop manager of 20 years, prepares most of the signs blanks. Once the blank is created it is left a couple days to allow the glue to cure, The panel is then run through a surface planer to level the laminations and remove excess glue.

Shaping

A full size template of the sign shape is plotted onto paper from the design and transferred onto the prepared sign blank. Depending on the sign size and shape, the sign profile is then cut with a radial-arm saw, table saw or bandsaw.

The wood is then coated with a thinned coat of special oil based primer, formulated specifically for oily wood such as cedar. After 24 hours, the surface is lightly sanded and re coated with a thick layer of primer. This final coat cures after a couple more days and then it receives a final light sanding.

Sandblast Stencil

Now the sign is ready to have the rubber mask applied. The design of the sign is either pre-cut on the mask by a rubber cutting plotter or hand drawn on the mask and cut manually with a stencil knife. The adhesive backed rubber is rolled onto the sign. The stencil is removed from the areas of the pattern that require a textured carved finished appearance.

Sandblasting

Now that certain areas of the stencil are removed, the panels are moved to the sandblast booth to be sandblasted. Here Warren is well protected under a sandblast suit and hood with a fresh filtered air supply being pumped into the hood. A 210 cubic foot per minute diesel screw compressor supplies the pressure to project the high velocity silica, walnut shell or glass beads that carves out the exposed areas on the sign, resulting in the contoured rough texture and raised grain appearance.

Priming and Painting

The sign is moved to the paint shop. Carved areas are primed or cleared with spar varnish, depending on the desired finish. Varnish requires 3 coats over a 3-day period. If an enamel paint finish is desired, 2 coats of primer are applied over a 48 hour period. Once dry, the first of 2 sign enamel coats are applied. If a gradient colour field is desired, the enamels are thinned before being sprayed onto the enamel base coats.

After another day the remaining rubber mask is removed. The raised, smooth protected areas are now exposed, lightly sanded and ready to add enamel paint. Warren now hand-paints any areas that require full colour illustrations with some airbrushing added for certain effects.

Hardware

Stainless or wrought iron hardware is installed onto the signs before pickup or delivery. If posts are required then 4” x 4” cedar posts are prepared to match the sign. Warren will recommend the most suitable post system [/installation.html] for each sign depending on its location and purpose.