When we arrived this summer, our "to-do" list included production of new signs, so we got the materials ordered and waited for them to arrive. Wally gave us the specific type of routing templates to order and advice on the best router to use. His suggestions really kick-started the process here. It is great to know other volunteers who have done similar projects, as their experience makes it much simpler to start a project on a different refuge.
ColorCore comes in 8' x 4' sheets, has a thin colored layer on each side, with a bright white center. Once you cut through the outer layer, the white is exposed. This makes it perfect for making signs that never need to be painted and won't fade when exposed to the elements. We chose the standard FWS dark brown, though it is available in many other colors.
The key to making the signs is a lettering jig and a plunge router. The jig keeps the letters spaced and aligned correctly, and the router does the actual cutting.
|An assortment of letters.|
|"DO NOT". The "I" is a spacer.|
|Setting up test sign on plywood.|
|Routing letters into a sign.|
|Blowing out the cuttings.|
Some take a bit more time:
One challenge was that about half of the signs need arrows, and there was no arrow template in the kit. But we figured something out. Any guesses where the arrow came from?
We have about 35 signs to do, and we expect more requests as folks see how good these look. We expect to be making and mounting signs right up until we depart.