[Woodcarver] Requesting advice for a carved residential sign

[Ron Ramsey]

Hi Susan,

1.I would not recommend butternut if you want any natural wood showing.  It doesn't weather well.  It would probably work OK if you plan on coating the entire sign with a solid color paint. A good choice for a natural finish wood that takes this much detail well and holds up to the weather well would be genuine or Honduras mahogany.  Avoid Phillipine mahogany.  

2.The size would depend on where it would be displayed. On the side of the house, somewhere between 24" x 12" up to 20" x 30" would be a good size.  If it is to be displayed above or next to the driveway on a large rural property, then 3' x 2' would be a better size.

3.The best finish for weather is solid paint.  I don't like this look myself so I do my signs with natural wood showing except for the letters and images. Even the best clear finish, such as spar urethane, that sits on the surface will yellow and peel in the weather in a few years.  Sikkens is a little better but still prone to early failures.  This is mitigated if the sign will live in full or partial shade.  Sun is a sign's worst enemy.  Rain snow and cold are lesser problems.  I use a semi-transparent penetrating oil sealer such as Preservawood that contains a UV inhibiting pigment. Don't use Duck-Back Superdeck as it contains a hardener that causes the finish to sit on the surface and does not penetrate as well.  The penetrating sealer is very easy to re-coat periodically just as you would a natural wood deck. Varnish/polyurethane type finishes have to be sanded down to bare wood to refinish.  This is particularly difficult in carved areas.

4. I coat of Preservawood.  Allow to dry for 48 hours. With the paint I usually apply three coats. One coat primer- tint with color of next coat.  One dark base coat.  One highlight and blend coat.  Then I add final highlight accents in appropriate areas.

5. What I would charge for a sign like this in Mahogany would be:

24" x 12" -$650.  
20" x 30" - $1250  
2' x 3' - $2000.  This is only me based on my methods and style. It's hard to advise others because everyone will approach a project differently.

I hope this has been some help.  BTW, I have been teaching high relief sculptural carving classes at the Marc Adams School of Woodworking.  I would like to offer a sign carving class there.  If anyone of you are interested in taking this class, please contact the school and request it.  http://www.marcadams.com

Thank you and good luck Susan,
Ron Ramsey
http://www.carvedbyramsey.com

Be sure to look at the incredible nature inspired art jewelry hand fabricated by my wife, Karen Olsen Ramsey.  It's worth the time to take a look!
http://www.artjeweler.com


Hello to all, 

The CEO of the company where I work has a home in Michigan, and has asked me to carve an outside sign for their summer home. It will be attached to the siding, next to the front door, outside but under roof. They will attach it themselves, but I have a drill press and can put holes into the corners of the wood (not to close to the edges - I would assume). 

I have a 2" deep piece of butternut about 6 feet long (I can cut it down) and 18 wide. But I don't think it is appropriate for outside use. But maybe it is ...if I used a good outside finish? Except for deepening some shadows (using an oil paint - thanks Joe), I don't expect to apply any paint to it. 

If you could tell me: 

1. Can I use the butternut? If not, what wood do you suggest? 
2. They want the carving to have their house in the background, pier, lake and then a fish jumping out of the water, along with "Welcome to our summer home" on the bottom. What size do you think I should make the sign? 
3. What outside finish would you suggest? 
4. How many coats? 
5. Can you give me some idea on what I should charge them? It sure can't be the time it is going to take me. 

I have done relief carving in the past, but nothing that would ever stay outside, and not a sign, and never any words. So this should be a fun adventure. I'm really looking forward to learning a lot of new carving methods. I have until Spring to complete it (working on it in the evenings and weekends.) 

Right now, I'm gathering my forces, doing research, collecting pictures, viewing the educational DVDs that are on my shelf, putting sticky notes in all the important places in my carving books, regularly drooling over Mr. Ramsey's website, and asking for advice from you, my carving web friends, which I will print out and put in a folder marked (optimistically) " First Carved Residential Sign." 

Thank you in advance for any advice you can offer. 
Sincerely, 
Susan 

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