5 posts were split to a new topic: Making boxes en machination
I was asked to create a unique retirement shadowbox and flag display/challenge coin holder for a friendâs retirement. Iâve never made any of these beforehand and he wanted everything matte black. It was fun, but a challenge. I had to measure everything and cut it before engraving logo on side of flag display case. Itâs nerve wracking making something that may stay in the family for generations! the sticky note was just a placeholder until I got his picture mounted in there.
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Great work!! The file resolution you uploaded is small and hard to see the fine details however. The matte finish compliments the boxes well.
Thanks! I didnât realize the files came through so small so I updated the images.
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I created a sign for the barn that my daughter rides at to take when they go to horse shows.
It is 100% PVC with the exception of 4 connector bolts to hold the middle panel to the uprights and some brackets for the riders to hang ribbons from.
The backplate has pockets cut at .02" larger for the letters to nestle into. The letters were cut individually and then glued into those pockets. This is the front of the sign, there are letters on the back as well and the only difference is that the PVC in the grey area is not textured on the back.
The black pieces minus the logos are 5/4" (really 1") PVC trim boards that I cut recesses on and then glued together to form 2" pieces with mortises for the name board to insert into. The whole thing breaks down, feet included, for portability.
There was a lot of tiling, mirroring and a little double sided machining.
PVC is great for something like this. The glue ups are fast!
The name backplate is 60" between the verticals which are 17" wide and 34" tall.
I borrowed some of my daughterâs ribbons for some glamour shots.
With any luck this is the last project on my Pro XXL before the 5.1 Pro gets set up.
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Cullen that is superb
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Well done, Cullen great looking sign. Tell your daughter well done, too, I see a lot of blue ribbons hanging there 
Thanks. I hope the barn owner will be happy.
Thats only some of her ribbons 
I must say I could buy those ribbons for a lot less than what they really cost me. Itâs her passion though.
I didnât take too many pictures while in process but here are a couple.
I used a 2x4 sheet to cut the letters and the logo symbols. It is textured on one side which I didnât want for the letters so I cut them smooth side up.
This shows the vertical frame members with their various pockets cut before gluing.
Like I mentioned earlier they were mirror images front and back and then glued to make a single thicker piece. The inner vertical pieces had pockets for the board with the letters and the trim on it as well as on the opposite edge for the tabs on the logos to sit into. The cuts on the top and bottom of the verticals are for the short horizontal cross members which got glued in.
PVC machines great and its easy to fix mistakes. In a few spots the mortise for to receive those horizontal pieces was a bit too deep and would leave a gap. I sliced some thin bits of PVC and glued it to the mortise surface and then put the mating members in there. Since it was being painted black it kind of hides all that.
Paint on the machined surfaces doesnât look that great so I minimized that to ends and rounded edges more or less. There is probably something I could treat that PVC porous surface with to make it look nicer with paint.
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I love the workshop relief !
Whatâs the material size on the Workshop sign?
10" x 16" x 3/4". Donât remember exact machining times. Roughing and finishing toolpaths were at least 4 or 5 hrs. each. Of course the larger the job size, the longer the maching time. I used my new CIC SVC-30 bit for finishing toolpath which I thought increased the detail as opposed to my usual 1/8" ballnose bit.
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Awesome, what type of file import did you use on those?
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They are STL files into Fusion
Looks like youâve perfected the process Jim. Nice results⌠the detail in the truck is amazing!
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What is the second one supposed to be? They all look great!
Itâs pen/ink art work from my daughter.
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Beautiful work!! What material is the fire truck?
Your favorite material 15 lb HDU.
Itâs a crane truck.