First, we carve the signs on our CNC router out of high density urethane (HDU). HDU holds up much better than wood and won't warp, split, or crack because of the weather.

Next, we attach the carved HDU to MDO for added support. We cove the edges, which means we apply an epoxy mixture with a squeegee. This helps protect the sign from the weather. We often see signs (especially if they are made of wood) that are falling apart because the edges weren't properly sealed.

Now we paint the backs of the signs and lay them out to dry.

Part of the front of this sign has been painted. The gold color on the lettering isn't paint. It's called "sizing" and will be used to hold the gold leaf on the sign. Gold, silver, and copper leaf all come in thin layers for easy application. The sizing is basically the glue that holds them onto the sign.

This 3D carved horse has had primer applied and is ready to be sized for gold leafing.

This flourish had been primed and will be painted with metallic brass paint.

The horse and flourish are drying. After they are dry, they will be attached to the signs.

The rest of the sign has been painted and the smaltz (crushed glass beads) has been glued on. You can't really tell in this photo, but the blue background has smaltz that sparkle in the sun.

The black background on this sign also has smaltz. Finished at last!