This project was built and designed by Jason from PatriotDIY. It’s a fully manual approach to sign-making using a handheld router—no CNC required—showing that personalized woodworking projects are well within reach with just a few basic tools.
From design transfer to routing, burning, and finishing, Jason walks through each step with practical tips and techniques. The final result is a rustic, custom wood sign that makes a great gift or decorative piece for any space.
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Starting with the Right Material
Jason begins with a live-edge pine slab, chosen for its natural bark edge and visual character. The unique look of the live edge adds rustic charm, making the final product feel handcrafted and one-of-a-kind.
When selecting wood for this type of project, it’s helpful to think about grain, tone, and how any natural imperfections might enhance your design. Softwoods like pine are easier to carve but still durable enough for indoor signs.
Creating and Printing the Design
Before touching the wood, Jason starts with a custom design. He uses graphic design software to create a layout and logo, saving it as a PDF for easy scaling and printing.
The PDF is printed in a tiled poster format, allowing it to be taped together and matched up for larger signs. This approach works with any font or graphic, letting you personalize the layout to fit the wood you’re using.
Transferring the Design to Wood
With the printout complete, the design is transferred to the wood using graphite transfer paper. The design is taped in place and traced by hand, which creates clear, visible lines directly on the wood surface.
This method keeps things simple and avoids messy adhesives or difficult alignments. It’s also forgiving—if something shifts during tracing, the paper can be repositioned easily.
Routing the Outline and Interior
Jason uses a standard router outfitted first with a profile bit to carve the outline of each letter. This bit cuts clean lines and defines the edges of the text clearly on the wood.
After outlining, he switches to a straight bit to clear the interior of each letter. The goal is a uniform depth across the sign, with a smooth, even floor that enhances the overall readability and sharpness of the carving.
For tight corners and smaller letters, Jason sometimes uses a detail carving bit. This adds precision and helps maintain clean edges in areas that would be difficult with a larger bit.
Adding Texture with Fire and Paint
Once the carving is complete, Jason uses a propane torch to burn the inside of each letter. This adds bold contrast and brings a traditional, tactile feel to the sign. It’s similar to the Japanese technique of Yakisugi, though used here purely for effect.
For spots where the torch can’t reach easily—especially small letters or corners—satin black spray paint is used to fill in gaps. This achieves a similar look while keeping the contrast crisp and uniform.
To clean up the top surface, a belt sander is used to remove any overspray or excess burn marks. This reveals the clean wood grain while leaving the letters dark and textured beneath.
Finishing the Sign
Jason begins the finishing process with a coat of shellac. This brings out the rich tones in the pine and seals the burned areas without lifting the char.
After shellac, he applies multiple coats of semi-gloss polyurethane. Light sanding between coats helps eliminate bubbles and ensures a smooth finish that enhances depth and color.
This two-step finish not only improves appearance but also protects the sign from wear and moisture, giving it lasting durability—especially if used indoors or in covered outdoor areas.
Hardware and Hanging
For mounting, Jason installs heavy-duty D-ring hangers on the back of the slab. These provide strong support for the solid wood and are easy to attach to most wall types.
Using a speed square, he ensures the hangers are level and evenly spaced. A proper hanging setup prevents tilting and gives the finished piece a professional touch.
A Manual Project with Maximum Personality
Jason’s approach proves that you don’t need high-tech gear to produce beautiful, detailed woodworking projects. With a simple router, careful planning, and a few finishing techniques, it’s possible to create a sign that’s both personal and professional-looking.
Whether you’re making it for your own space or giving it as a gift, this sign is a satisfying project that lets you flex both your design and tool-handling skills.
Please support Jason by visiting his Etsy Store: https://www.etsy.com/shop/patriotdiy.