Low Density HDU Sign Build – CORAFOAM

We recently completed a low density HDU sign project. Here are the end results of this custom 3D custom signage challenge. Here are the end results in day time view.

Jacks Public House Restaurant  - Day Time View

Jacks Public House Restaurant – Day Time View

We use low-voltage LED lighting, which is an energy efficient outdoor commercial grade lighting solution. LED signage lighting offers twice the brightness at less than half the energy costs of traditional fluorescent lighting. Here are the results at night time view.

Jacks Public House Restaurant  - Night Time View

Jacks Public House Restaurant – Night Time View

This restaurant sign project had requirements outside typical signage boundaries. The sign project scope was to produce the top end of a wooden spirits barrel, with the typical wood burned distillation details as the business branding.

The owner of this restaurant wanted “something exceptional” versus “just something.”
This is right up our alley.

Here are the original sign design concepts:

Jacks Public House Initial Sign Design Ideas

Jacks Public House Initial Sign Design Ideas

There are many ways to approach such a project.High Density Urethane (HDU) is a sign industry standard substrate. In signage, HDU started as a substitute for wood (redwood, then cedar after redwood became less available) for sandblasting signs. Technology advanced with CNC (Computer Numerically Controlled) router machines, which greatly impacted the Signage Industry.

The combination of HDU and computerized tooling opens combinations only limited by artisan imagination. You can see how we can create a dynamic wood grain effect in HDU, simply from drawing lines on a computer.

CORAFOAM CNC Route

CORAFOAM CNC Route

Taking the original design concept, we then had to approach project scale. The wall area of this project was 8’ tall x 18’ wide. Local Sign Code granted the business owner a sign 7’ tall x 12’ wide. There were no restrictions on thickness, nor lighting effects.

We started production with dual-level halo backlit LED lettering.

Back-lit Halo Letters Back

Back-lit Halo Letters Back

Back-lit Halo Letters Front

Back-lit Halo Letters Front

Here are the letters lit up, at both levels, as stand-alone elements before attaching to the main signage structure:

Back-lit Halo Letters Glow

Back-lit Halo Letters Glow

The signage structure barrel HAD to be lightweight, yet hold detail of 3D effects. Duna Enterprises, a manufacturer of HDU, recently launched CORAFOAM. CORAFOAM is an appreciated spin-off of their established 15 pound density product at on 2 pounds per cubic foot. Here are pictures of the HDU elements we layered to build the sign structure:

CORAFOAM Sign Pieces Assembly

CORAFOAM Sign Pieces Assembly

CORAFOAM 3-D Sign Initial Progress

CORAFOAM 3-D Sign Initial Progress

Here is a picture of the sign body being assembled. We integrated PolyMetal and PVC for additional structural support.

CORAFOAM 3-D Sign Assembly Progress

CORAFOAM 3-D Sign Assembly Progress

For a sign project this large and this high in the air, CORAFOAM was the obvious solution. Here is a picture of the project with someone beside it to show scale:

Jacks Public House Sign Scale

Jacks Public House Sign Scale

Here are production shots as we built the main barrel portion of the sign using CORAFOAM. We designed a custom, random wood grain pattern to CNC route as this was to be very high in the air. The deeper the dimensional effects, the better.

CORAFOAM CNC Routed Wood Grain Pattern

CORAFOAM CNC Routed Wood Grain Pattern

Here is the project in finishing stages being hand painted and faux finished.

Jacks Restaurant Sign Artist Painting

Jacks Restaurant Sign Artist Painting

The finished sign project was assembled and wired for lighting flat for simplicity. This allowed for all of the lighting effects to be tested individually before delivery to the job site.

Jacks Restaurant Sign Artist Painting Complete

Jacks Restaurant Sign Artist Painting Complete

This sign was to be installed 20 feet in the air on the business facade. We built a custom lift crate, and hoisted into position.

Public House Restaurant Sign Install Lifts

Public House Restaurant Sign Install Lifts

This project would never have happened without the partnership of Mark Sundermeyer of Two Minds Artistry, and Michael Roebuck of Absolute Signs.

Mark Sundermeyer Sign Install

Mark Sundermeyer Sign Install

Michael Roebuck Sign Install

Michael Roebuck Sign Install

Wade Parker Sign Install Lift

Wade Parker Sign Install on Lift – Scared of Heights

We are a collection of artists that can produce beyond outstanding results. While we are based in Atlanta, the majority of our work is shipped out of state. We welcome any challenge.

Check out our 16 page completed sign monument portfolio with hundreds of kick ass sign examples!

Our team is a collaboration of artists with decades of experience in the dimensional signage and sign monument industry. Your project will be designed and suited to your needs. Let us brand the individuality of your company or property.

Our focus is to design, produce, and deliver the Best sign products.

Our goal is to make you look your Best, and to save you unnecessary expenses.

We offer personal service, creativity and value.

Our custom restaurant and commercial sign solutions provide a sense of distinction. With over (2) decades of nationwide success, we will make You Look Your Best!