learn the facts here now Here is a quick peek into how I build my 3-foot Montana wood sign from reclaimed pallet wood.
http://daviddmorse.com/christ/our-warped-understanding-of-association-with-god/ I start with some nice hardwood aged pallets. Just a little sanding uncovers some beautiful wood grain in reclaimed pallet wood. The first picture is a piece of the wood before sanding.
In the second picture, the right side is sanded and the left side is not.
Here is a closer look at the pallet wood. The grain is wonderful and the cracks, nails, and chips all add to the character of the wood. I use this wood because I want to make a sign that looks like it has aged naturally and I don't want to apply any faux finish or distress the wood.
Next I layout the cut pieces and roughly fit them together. Again, I could plain the edges and make a perfect fit but that is not the look I am going for.
I apply the lettering and do any detailed work I need to do on the Montana wood sign.
Next, I refit the boards together and run railing on the back to fasten the sign together. Depending on the weight of the sign, it will either be hung with a sawtooth hanger or D-rings and picture wire.
The 3 in 1 pneumatic staple gun was a huge time saving addition to my wood shop. Before I had this air stapler, everything was done with a hammer and nail. Nailing by hand was a slow process and I ended up breaking a lot of boards and bending a lot of nails.
I then finish the edges. The edges of these aged boards need to be finished in some way because they are fresh cuts so they stand out like a sore thumb. I use a few methods but mostly I have been using the burn method. I toast the edges with a propane torch. I have also painted the edges of my wood signs, stained them, and used a vinegar and steel wool solution on them to turn them grey.
To finish the rustic wood sign I will apply a light coat of matte clear coat protectant. Once it has dried I like to dust it with Old English furniture polish which gives it a little more depth and richness.