A couple years ago we had the opportunity to create two signs for the Ron Clark Academy in Atlanta. As a result, the principal of the Bronx Lighthouse Charter School in NYC was visiting the Ron Clark Academy and was inspired by our signs and came back to his school with an idea and he got in touch.
He sent us this concept of the anchor, wheel and his school logo.
We took out the chain and added textures and layers.
Once approved, we began designing all the pieces to cut out on the CNC out of 15 lb. HDU.
After all the pieces were cut out, then the fun could begin in shaping and sculpting and assembling all the pieces.
This was a big sign. 8 ft. wide by 8.5 ft. tall with 4 layers. We had our friends at Welding Works weld up some steel c channel into a frame that was embedded into the back of the anchor that all the layers would be bolted to.
We used hand tools and power tools to shape the parts.
The anchor needed to look like an old rusty surface, so we experimented with different tools to create a pitted surface. The guys arms were getting tired as you can see.
Finally, we could assemble all the pieces and see how it looks!!
Next, it was time to paint and detail!!
We used some epoxy gelcoat and casted these little domes to use as hardware on the iron band.
The design concept was to limit the materials to weathered wood and metals. For the anchor and the metal band, we used Modern Masters iron rust paint. For the lighthouse logo, we used Modern Masters bronze and copper with their green and blue patina sprays. For the old wood, we painted it black first and then dry brushed medium and light toned browns over the black.
Letters were .5″ acrylic laser cut and painted.
We used glue and screws and bolts to put it all together.
Yeah!! We finished on time!!
We built a shallow plywood frame to attach it to for delivery to NYC where the school maintenance will install it.
Another satisfied customer!! This was a really fun sign to make!
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