1. First Project: A Sign Principles of Manufacturing 1 Copyright © Texas Education Agency, 2012. All rights reserved

2. Sign The first project that will be produced is a sign. 2 Copyright © Texas Education Agency, 2012. All rights reserved

3. All the basic machines will be used to produce the sign. The students will operate:  scroll saw  band saw  drill press  router 3 Copyright © Texas Education Agency, 2012. All rights reserved

4. Plans The sign will be made from a piece of 1 X 4 wood. The finished sign should be no less than 13 ¾ inches. Drill two ¼ inch holes in the back of the sign for hanging. Drill the holes 3/8 “ deep from the back. Both ends are the same. 2”¼” to ½” 4 Copyright © Texas Education Agency, 2012. All rights reserved

5. Alternate Designs The shape of the sign can be changed to personalize the project. The name will be something the student chooses to engrave on the wood. 5 Copyright © Texas Education Agency, 2012. All rights reserved

6. Layout Grid The “Sign Layout Worksheet” has a grid on which to design your sign. The grid is half scale or one square equals ½ inch space. 6 Copyright © Texas Education Agency, 2012. All rights reserved

7. Sign Worksheet Check off the steps in “Steps in Production” as you finish it. Use the edge shape box to choose the design on the edge of the sign. The Grading Rubric is for you and the teacher to evaluate your sign. 7 Copyright © Texas Education Agency, 2012. All rights reserved

8. Sign Worksheet Name ________________________________ Date ______________ Period _____ Grading Rubrics StatementNumberStudent Teacher The sign matches the layout 25 points max The design is personalized 15 points max No saw or machine marks 15 points max marks –3 each No sanding marks 20 points max marks –1 each Sign length 13 3/8 to 14 inches 10 points max if shorter no points Yes No Finish 15 points Total ___Round over ___Bead ___Roman Ogee ___Cove ___Bevel ___No Shape Select an edge shape for your sign. Place a check mark on your selection Steps in Production ___ select a sign blank ___ lay out the design on the wood ___ cut on scroll saw or band saw ___ remove saw marks with file of sandpaper ___ select the edge shape from the guide on this page ___ place router bit in the router table ___ rout the edge of the blank ___ course sand all surfaces of the sign with 80 - 100 grit sandpaper ___ layout the text of the sign measure in from each side of the sign so that a letter height of at least 1 inch is left ___ draw the lettering in between the guidelines ___ rout the letters into the sign using an engraving bit ___ course sand the engraved surface removing marks of burred edges ___ medium sand all surfaces of the sign with 120-180 grit sandpaper ___ fine sand the sign with 220 grit sandpaper ___ clean with a rag for finishing Staining and Finishing ___ select stain color for the sign ___ apply stain ___ wipe excess stain from wood ___ allow wood to dry 12 hours before finishing with a clear coat ___ wipe stain wood with a clean rag to remove dust ___ apply on clear finish 2 or more coats Painting ___ apply primer and allow to dry ___ apply paint 2 or more coats ____ fill in the rubrics at the bottom and have the teacher grade it 1. “Steps in Production” 2. Illustration of edge shapes 3. Grading Rubrics Grading Rubrics Statement Number Student Teacher Does the sign match the layout. 25 points max The design is personalized. 15 points max No saw or machine marks 15 points max marks –3 each No sanding marks 20 points max marks –1 each Sign length 13 3/8 to 14 inches 10 points max if shorter no points Yes No Finish 15 points Total Grading Rubrics Statement Number Student Teacher Does the sign match the layout. 25 points max The design is personalized. 15 points max No saw or machine marks 15 points max marks –3 each No sanding marks 20 points max marks –1 each Sign length 13 3/8 to 14 inches 10 points max if shorter no points Yes No Finish 15 points Total 8 Copyright © Texas Education Agency, 2012. All rights reserved

9. Edge Shapes ___Round over ___Bead ___Roman Ogee ___Cove ___Bevel ______ No Shape Select an edge shape for your sign. Place a check mark by your selection. 9 Copyright © Texas Education Agency, 2012. All rights reserved

10. Grading Rubrics Statement NumberStudentTeacher The sign matches the layout 25 points max The design is personalized 15 points max No saw or machine marks 15 points max marks (–3 each mark) No sanding marks 20 points max marks (–1 each mark) Sign length no less than 13 ¾ 10 points max Yes No Finish 15 points Total 10 Copyright © Texas Education Agency, 2012. All rights reserved

11. Steps in Production Draw the design on the “Sign Layout Worksheet.” The instructor will give you a sign blank when you have the layout finished. Transfer the design to the blank using a ruler and other layout tools. 11 Copyright © Texas Education Agency, 2012. All rights reserved

12. Steps, Continued Cut one end of the sign on the scroll saw. Cut the other end using the band saw. Use a file to remove the saw marks on the edges of the sign. 12 Copyright © Texas Education Agency, 2012. All rights reserved

13. Steps Continued Use the edge shape guide on the “Sign Worksheet” and select the edge shape. Place the router bit that matches the shape in the router. Rout the edge on the sign. 13 Copyright © Texas Education Agency, 2012. All rights reserved

14. Steps Continued On the back of the sign. Measure for both mounting holes. Use a ¼ inch drill bit and drill 3/8 inches deep into the back surface. The holes are 2 inches from each end and 3/8 to ½ inch deep for holding the sign to the wall. 14 Copyright © Texas Education Agency, 2012. All rights reserved

15. Steps Continued Coarse sand all surfaces of the sign with 80 – 100 grit sandpaper. Lay out the text on the front surface of the sign. 15 Copyright © Texas Education Agency, 2012. All rights reserved

16. Drawing Text on Sign Measure in from each edge of the sign the same distance. Draw a straight line down the length of the sign. 16 Copyright © Texas Education Agency, 2012. All rights reserved

17. Text Draw the text between the lines, centering the text on the sign. 17 Copyright © Texas Education Agency, 2012. All rights reserved

18. Rout the letters into the sign using an engraving bit or other approved bit. MLCS Router Bits and Woodworking Products 90 degree V-groove bit ¼ “ round nose bit ½” 60 degree V-groove bit ½” round nose bit 18 Copyright © Texas Education Agency, 2012. All rights reserved

19. Engraving the Letters Place the sign in the vise to hold it. Make sure the surface to be engraved is up and above the edge of the table. The router must not hit anything while the sign is being routed. 19 Copyright © Texas Education Agency, 2012. All rights reserved

20. Guide the router to freehand cut the letters. Coarse sand the surface to remove stray marks and burrs on the letters. Medium sand the complete block using 120-180 grit sandpaper. 20 Copyright © Texas Education Agency, 2012. All rights reserved

21. Fine sand all sides of the sign using 220 grit sandpaper. Clean the dust off the surfaces with a clean rag. 21 Copyright © Texas Education Agency, 2012. All rights reserved

22. Use the information about finishing a project to apply the finish. After finishing the sign, fill out the “Grade Rubric” on the sign worksheet. Turn in your sign and sign worksheet to the teacher. 22 Copyright © Texas Education Agency, 2012. All rights reserved

23. Enjoy completing the sign project! 23 Copyright © Texas Education Agency, 2012. All rights reserved

24. Resources Web Sites on Woodworking Rough Cut – Woodworking with Tommy Mac http://www.thomasjmacdonald.com/ American Woodworking http://americanwoodworker.com/default.aspx Wood Magazine http://www.woodmagazine.com/ MLCS Router Bits and Woodworking Products for the picture of router bits slide #21 Pictures from Manufacturing Class students Plans drawn with Google Sketch Up 24 Copyright © Texas Education Agency, 2012. All rights reserved