It is hard to believe that it was only seven years ago I witnessed a CNC router in action for the very first time. I was fascinated and simply had to have one! Although I had been in the creative end of the three dimensional sign business for most of my life I didn't really know what I would do with one - but I just knew it could do fantastic stuff.

Through extensive research I quickly found out that with the relative simplicity of EnRoute, CNC routers were capable of just about anything imaginable. This journal will chronicle that journey to date and continue each week with two or three entries as we continue to explore just what is possible with this wonderful software... -dan

Monday, August 8, 2011

Sculpting and more sculpting

The hunt master's horn was the next piece to be created for the Master's Bugle sign. The basic shape was designed in EnRoute in two halves. It was roughed out on the MultiCam using a 3/8" ball nose bit with a 50% overlap. I didn't need a smooth shape because I was going to cover it with Abracadabra sculpting epoxy

The first step was to press on a rough coat of sculpting epoxy. It acts as a primer coat.

Then it was time to sculpt the horn and 'metal' embellishments. The thing about sculpting epoxy is that the more you work it the more it softens up. The cure is to let things sit for a while, then come back and straighten things up.

The clearances are tight so I fastened it in place while it was still soft., adjusting things as needed. The hunt master's horn was well worn, somewhat dented. It would have been used while on horseback and most likely survived a tumble or two.  

At the job site things continue to proceed. Inside we are painting. Outside, the first side of 'brickwork' was troweled into place and carved today.