After almost ten years after making the first two sets of JOY yard signs, Stephen requested another joint effort to create two more sets. One of these sets would go to Andrew and Megan, and the other set would go home with Stephen, as a surprise early present to Katie. The plan was to finish them in time to present them after our family Thanksgiving dinner.
Stephen and I worked for nearly a whole Saturday, from acquiring the plywood at Chelsea Lumber through getting the first coat of red and white paint on all of the components. This time, Stephen brought his own jigsaw, so our cutting out time was literally cut in half! The signs ended up being completed in time for the Thanksgiving day presentation!
A full scale layout in SketchUp showed that a whole sheet of plywood would be needed for each set of JOY yard signs
A full scale layout in SketchUp showed that a whole sheet of plywood would be needed for each set of JOY yard signs
3D view of full scale layout
3D view of full scale layout
Measurements of existing JOY sign letters for scaling in SketchUp
Measurements of existing JOY sign letters for scaling in SketchUp
The ten year old Mahan set of JOY sign letters still look good and were used as patterns to reproduce this year’s sets
The ten year old Mahan set of JOY sign letters still look good and were used as patterns to reproduce this year’s sets
After disassembly, Stephen traced the existing letters onto a fresh sheet of AB fir plywood
After disassembly, Stephen traced the existing letters onto a fresh sheet of AB fir plywood
Climbing up on the workbench provided a better body position to cut out some of the letters
Climbing up on the workbench provided a better body position to cut out some of the letters
Sharp blades in the jigsaws made quick work of the 3/4″ plywood sheets
Sharp blades in the jigsaws made quick work of the 3/4″ plywood sheets
Stephen is very artistic and handled cutting out all of the small details
Stephen is very artistic and handled cutting out all of the small details
A bit of sanding and all the letters and other components were ready for their first coat of paint
A bit of sanding and all the letters and other components were ready for their first coat of paint
Closeup of Stephen’s handiwork on the detailed figures
Closeup of Stephen’s handiwork on the detailed figures
A small foam roller and foam brushes worked well for applying the paint and made for simple cleanup afterwards
A small foam roller and foam brushes worked well for applying the paint and made for simple cleanup afterwards
Applying white paint to the components that will be attached to the “O” letters with stainless steel wood screws
Applying white paint to the components that will be attached to the “O” letters with stainless steel wood screws
Almost ready to flip everything over on painter’s points and start painting the front surfaces and edges
Almost ready to flip everything over on painter’s points and start painting the front surfaces and edges
It was satisfying to see all the letters and components with their first coats of paint on the same day that we brought the raw plywood into the workshop
It was satisfying to see all the letters and components with their first coats of paint on the same day that we brought the raw plywood into the workshop
I am determined to me more discerning about what scrap wood gets to stay in the workshop after every project
I am determined to me more discerning about what scrap wood gets to stay in the workshop after every project
Fortunately, there was enough red and white paint left over from other projects to complete these two sets of JOY yard signs
Fortunately, there was enough red and white paint left over from other projects to complete these two sets of JOY yard signs
Second coats of paint complete and after some drying time, ready for final assembly
Second coats of paint complete and after some drying time, ready for final assembly
Final assembly of the “O” letters and an example of the 3/4″ conduit clamps to hold the letters on the 1/2″ round steel concrete forming stakes
Final assembly of the “O” letters and an example of the 3/4″ conduit clamps to hold the letters on the 1/2″ round steel concrete forming stakes
The final presentation of the JOY yard signs after a wonderful Thanksgiving meal with nearly twenty loved ones at the table!
The final presentation of the JOY yard signs after a wonderful Thanksgiving meal with nearly twenty loved ones at the table!