We started this project with a sketch- like every other project we do. A simple, pencil sketch that sheds light on what has come to mind for your project, but doesn't reveal too many details.... and allows us to embellish the plan from the time we discuss your ideas and work out a budget to the time it ends up on your wall.

Today at 5:45am we started the installation, and thanks to planning our attack last night, we had the job completed before downtown Estes Park was inundated by tourists and locals on the way to work. That's the way we like it!

Tip: get up early to see, smell and really appreciate Estes Park in the summer- without crowds, without traffic jams and without any hassle while you soak in this great community without bother... About 7am things begin to change, though.

The sketch will soon turn into a fancy sign that sets this store apart from the competition...

We used the MultiCam CNC router on this job to cut out the outline of the pony, from multiple pieces of HDU that we'd pieced together (for more about how the pony was created, click the 'Older Posts' link at the bottom of this page for the previous blog entry). The pony was shaped and finished by hand once past this rough cut out was complete.

Once the panel was built and painted, we masked off the parts we didn't want to be covered in crushed glass (smalts).

On top of the blended paint base, the glass is scattered across the panel and left to set for several hours, until the mask is removed and the clear areas are revealed that will be lettered or have the pony affixed in place, creating a nice outline of rough glass around each element of the sign.

Nearing 90 degrees yesterday, we opted for the final assembly in the shade of the driveway. Trevor is affixing the trim after we set the pony in place and finished the steel standoffs for the irregular installation.

At 615 am, we're positioned to install this sign, another little bird leaving the nest. The irregular part is that pesky drain spout that projects 5" from the wall! We built the frame to float in front of the drain standing off of the wall several inches. This will be the material handlers last job- as you'll see shortly... 

This will become one of those projects we'll reflect back on fondly- come December or January when we're up on a wall, in coveralls and hats and gloves and sliding around on ice... I love THESE days!

A real jewel of a sign, that will be good for the client, and for us, showcasing the style of work that we enjoy the most.

Oh, on the way back to the Rent All (taking the material handler back before they even opened for the day) there was a big cloud of smoke, a chug-chug-chug, then it felt like the machine ran into a brick wall, and came to a stop in the center of Highway 7. I was pretty sure that it would burst into flames any second, but it didn't. I directed a few cars around while I made a few calls to try and get a machine rescue arranged. The police showed up, and and the Rent All folks stopped by on their way to work and took over. I paid the rental bill and got back to the shop, in time for a full day of work at 830am..