![]() Dry them as soon as possible because they will rust quickly if you don't. Once dry, use a 100 or 120 grit flap disk to polish up the metal and smooth out any rough edges. ![]() Let them sit for about 10 minutes and then rinse in water with a little baking soda to neutralize the reaction. To remove the greasy film on the metal I soaked the letters in muriatic acid. I decided to give all the letters and designs a bright polished look. I set all the designs on the metal to see how everything looked. Here is a look at the back panel cut to size and the completed circle. You can also chip away slag using a hammer and metal chisel. I typically use an angle grinder with a flap or grinding disk for this process. Make sure to remove the decal prior to cutting because it will burn up and stick to the metal.Ĭutting letters by hand takes some time, so take a few breaks during the process and make sure you have good ventilation.Īfter the designs and letters are cut you'll want to remove the slag. This gave me a good visual to follow with the plasma cutter. After applying the decal I traced around each letter and design using a sharpie marker. Here is the outline of the microphone in the Entrepreneur On Fire logo.īelow are additional stencils for the San Diego silhouette and words. Wear plasma cutting eye goggles and a respirator. Here I am following the outline I drew of a circle. I used the Hobart 250CI plasma cutter that simply plugs into a normal 110V wall plugin. You just have to follow the lines you drew and make sure to hold the tool as steady as possible. Time to get out the plasma cutter! This tool is a blast to use and is very easy to master. I created a separate stencil to create a perfectly round metal circle. Vinyl stencil of the EntrepreneurOnFire logo. I got my Graphtec 24″ vinyl plotter here. This is seriously one of the handiest pieces of equipment and if you are into metal working you'll be able to create any stencil you'd ever need. Next, I created stencils using my vinyl plotter. The total cost for steel was right around $95. I also purchased 1 inch square tubing to frame out the piece. I picked up 10 gauge steel for the panels on this project and used 12-14 gauge for the letters. The sign is 64 inches wide and the circle is 18 inches in diameter. I came up with an idea for the project and created it to scale in a program named Adobe Illustrator. Stencils for the design – I made mine using my Graphtec CE-6000 Vinyl Plotter Two part epoxy Chain, eyebolts, and metal clasps Cleat to hang project Step 1 – Design Spray paint Metal Sealer – (Available at any hardware store) Metal – 10 gauge for panels - 12 to 14 gauge for lettersģ/8 inch threaded rod, nuts, and washers for layering metal Hobart Flux Core 110 Volt Welder Hobart 250CI 110 Volt Plasma Cutter Dewalt Chopsaw Dewalt Angle Grinder 20 Volt Dewalt Angle Grinder (the battery powered version) – Super awesome tool! Supplies used I did a little photo shoot/video on top of a mountain and had some fun. I wanted to incorporate his name as well, which is why I added the chains and plaque. The metal on the right is the San Diego skyline. To personalize the sign I created a cutout of Maine on the left side. I used a cleat system to hang the sign which made it super simple to get on the wall. ![]() Here is a video tutorial that shows an overview of the build. ![]() It weighs 80 pounds and is nearly 6 feet wide by 2 feet tall. In this tutorial I will show the basic steps I took to build this metal sign. I could incorporate multiple layers of metal, a city skyline silhouette, map, and fire! I had an idea for a project that I wanted to make and John's business was the perfect fit. This means you'll be helping support more free DIY Projects and that my site will earn a commission if a sale takes place. *Disclosure: Please note that some of the links placed in this article are affiliate links. Crazy huh?!! He's even started a podcasting community called Podcaster's Paradise to help others learn how to podcast and I'd highly recommend it. His podcast is getting over 500,000 downloads per month and is generating over 6 figures each month. A fellow podcaster and friend John Dumas owns a wildly successful company named which promotes entrepreneurship using a podcast. This week's project is one I'm very proud of and like no other I've ever created. ![]()
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