Soooooo, this was another “me” project. I recently moved into a newer, smaller place that didn’t require the need for an actual kitchen table. The kitchen countertop warranted the need for a high-top chair or stool in order to be purposeful. So I came up with a few variations and ultimately settled upon this design. I originally set out to create something simple while still looking complicated. The goal was to create a design that was easy to make, yet complicated to the untrained eye…..if you know what I mean. This was the winner. The seat and foot rungs are made of solid maple and the legs are made from an inner core of pine, skinned with an outer layer of 0.125″ Baltic Birch plywood.
Concept images created in Cinema 4D.
Rustoleum’s “Poppy Red” spray paint on plywood.
The back side of the 3/4″ plywood blank has a 45º bevel.
1/2″ plywood laminated with 1/8″ styrene is the base for the characters.
Characters are cut using a 1/8″ endmill router bit on the CNC.
Using the same 1/8″ router bit, I cut a profile path for the characters that were previously cut.
The profile cut of each character is set to 0.25″.
I cut the outside profile of each character deeper than the rest because I’ve found that it minimizes tearout in the plywood. It also gives a little bit more depth to the cavity behind each character.
At this point, I’ve applied paint mask over the red surface so that I protect it from the black paint that is applied to each character cavity.
Sooooo at some point, I must have dropped something right in the middle of the work piece….it looks worse than it actually is but it’ll still require a little bit of work to fix….
A little bit of wet sanding and more paint and we’ll be good as new!
The stripes at the bottom of the plaque have been painted and we’re just about finished!
The Blackhawk head is a custom sticker that I created just for this project.
Hmmm…..why didn’t I just paint the entire cavity black?…..
I positioned pieces of tape in the character cavities as a mask to keep spray paint out. Because I glued the characters to the sign blank, I wanted to make sure that I had a nice, secure hold onto an unpainted surface.
Can’t forget my logo, website and date!