DIY Outdoor Sign with Double Sided Double Inlay

 

Total time: 16hrs

Difficulty: Expert

Cost: $250


TOOLS USED

MATERIALS USED

  • Maple
  • Cherry
  • Walnut
 

How to make an amazing sign that will turn heads?

I just love challenging projects and this one was no exception. A friend reached out and wanted a really cool sign for his driveway. Originally we talked about doing it in cedar but after convincing him to let me try to do a double sided double inlay.. the challenge was on! 

I have never done an inlay like this from scratch. So from the design, to the v-carve operations, this was all new to me. A few things I learned along the way were to make sure you don't have your 1/8in and 1/4in bits mixed up.. :D. Also, during glue up make sure you have as even pressure as possible when clamping. The other thing that I found that's really important is make sure you leave yourself a small glue gap in the bottom, otherwise you will have issues getting the inlay to seat properly.

I used my new Klingspor 1/8 downspiral for the bulk of the inlay removal, followed up by he 60deg v-bit to clean up the edges. I am super happy with this "first try" and look forward to doing more in the future!

 

Now, I know what you're thinking... "I don't have a CNC"

No problem, you can accomplish the same project with a scrollsaw and you won't need to do the 60deg bevel.

 

Zach's pro tip

When doing a double inlay, meaning your first inlay gets another inlay on top of it, make sure the first one is a deeper inlay then the second. For instance, make the first one .2in deep and the second one .1in deep.