Start with making a sign blank. Sandblasted signs are mostly made of  sign foam or soft wood such as cedar or redwood. If using rough lumber plain all 4 sides then cut to the size you need for your sign blank. Next laminate  the boards together using  glue and clamps.

After the glue on the sign blank has set, sand it smooth and clean the side you will be applying the sandblast stencil to. 

Position and clamp the sign blank on your table making sure that it is square to the machine

 

Now cut a piece of Sandblast stencil a about 1" larger than the sign blank,  then remove the backing material from the Sandblast stencil and position it on the Sign blank and squeegee it down. You do not have to press the Stencil to the blank too firmly, just enough remove any high spots and to hold it in place while cutting, to much pressure will make it harder to weed.

Install the Vinyl Mate in the routers collet and run the part file you designed for your sign. This much easier than cutting the stencil first then trying to transfer it onto the blank (something you can't do on a plotter machine)

 

Carefully weed out all the sandblast stencil that isn't needed, then firmly press the Stencil to the sign blank.  (A jay roller works well for this.)

 

Sandblast the sign to the desired depth, Making sure that the the nozzle stays at 90 degrees to the Sign blank. if you blast on an angle you will blast away the material under the Stencil ( undermine ) Also there is a chance of lifting the stencil.

When the desired depth and appearance is reached, blow off the sign to remove any lose sand. 

Carefully remove the rest of the stencil. Cedar lifts and splits very easily so don't get in a hurry when removing the stencil.

Fill any cracks or spots that may have lifted with wood filler and sand smooth.

For this Sign we applied a clear coat, a minimum of 3 coat should be used. All the wood must be sealed so when you apply paint on any part that isn't sandblasted (e.g. letters) the paint will not bleed into the sandblasted area.  When using a clear use one that is mildew resistant or one that contains mildewside, also the clear should have a ultraviolet inhibiter.

Due to the harsh environment that a sign is in, in time it will darken somewhat and in some spots where mildew starts in can turn a dark red or even turn black. This in some cases can add to the looks of the sign.

A variety of stains or paint can also be used.

Now using a sanding block sand smooth all the areas to be painted being careful not to break any edges off. This will prepare the surface for paint.

Apply paint to the unsandblased areas. Sign painters one shot lettering enamel is a good paint to use and one coat is sometimes enough. It can be purchased at any sign supply store

 

 

Finished Sign