Carl has sent some additional information to help clarify how he made this sign, plus a very interesting tip on how to design signs that people will look at.
I would like to clarify: Bucky is not ‘a part of the sign’ Bucky is simply a separate 3d carve that is doweled and glued to the sign. Reason is I wanted Bucky to be a 3rd dimension higher than the rest of the sign. To create the cut outs I simply traced the bitmap of Bucky and incorporated it into the rest of the art so the vcarving on the outline would not carve away wood under Bucky.
Lastly, most of my signs have holes in them similar to my head… Seriously, like a flag or banner, our eyes ‘see’ movement and we look at it to investigate it, good movement? Bad movement, runaway? My theory is if as we move past a sign with a hole in it we perceive the background behind the sign, through the hole to be moving and our eye focuses on the movement. Even if it is not true, it sounds good to the customer and separates my work from others. In the past when I did it and it was tedious, now with a ShopBot, it is easy.
I promise I will register soon…..