Hand Routing Signs

In this instructable, I would like to show you the technique I use to hand router signs for people. There is a list of materials which are readily available and don’t cost the earth... this technique does require practice so have patience but you can get great results! A full video walkthrough can be found on my YouTube channel, link on my profile.

Hard wood or soft wood,
Palm router
1/4” 45 degree V groove bit
Roman ogree bit or round over for edge banding
Sander with 120-240-320 grit sand paper
Printer
Celotape
Paint
Stain

Here I am using a hardwood, Elm, for my sign. I am giving the piece a quick sand with 320 grit sand paper in my orbital sander, you can use a hand sander or what ever you have

I create a template to router in a word document on my computer. Using the ruler guide on the word programme I can get a good idea of size and layout before I print it out. Once it is printed and excess paper trimmed off the template, I like to use a 2” clear tape to secure it in place on the workpiece. I have tried double sided tape but didn’t like it, this is quick and effective.
Take your time though. You don’t want wrinkles, it needs to be smooth

Once you have made a couple of test cuts to set the depth with the V groove bit, you are ready to cut your template. Go steady, start at the top of the letter and work down. I like to hold the router at the base plate, keeping the edges of my palms touching the workpiece to keep me steady. Get so you can see what you are doing safely and wear the necessary PPE.

Now the sign is ready for paint, before we paint though we need to seal it to stop bleed of paint. I like to use a clear spray lacquer but I know others use PVA or modge podge to prepare. Once that is dry you can paint with whatever colour you like. Once it’s dry you can sand the excess off, as you can see in the pics, there is no need to be delicate when painting...

Now the paints dry and the excess is sanded off we can finish the piece. I use multiple finishes often depending on where the sign will be kept and what the customer wants. I have a dark, oil based stain for external pieces, a wax polish that dries clear for internal more natural looking pieces and also the clear lacquer. This gives it a constant wet look sheen which some people like. Make sure you trial a few different stains to pick what work for you.