Tiki Room Sign

When I visited the Magic Kingdom at Disney World, I took many pictures of the sign that is outside of the show. I recreated the sign to be 90" long (almost full size) in Fusion 360 (a CAD program) and cut it out of foam on my CNC. Since I could not find 2" foam, I had to glue 2 - 1" pieces of foam together, which created problems with the glue drying and pieces falling off, where the glue was not strong enough. I still have to assemble it and paint it. This summer I spent many evenings painting the sign and even purchased an airbrush to hone in on the colorations and blending I was looking for.

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Tiki Room sign that I created in Fusion 360.

Screenshot of the Fusion file highlighting the tool path, and how it is broken up into 3 sections

View of the 1" insulation sheets inside of my vehicle

I couldn't find two inch foam, so I had to glue 2 one inch sheets together - this is the sheet with glue on it

I placed heavy stones on top of the sheets of foam, the glue expanded, soI had to weight it down.

Glue is dry, I cut it down to size, and starting to cut it on the CNC

Video of it cutting on the CNC in my garage

The 1st panel is coming along as the layers are slowing cutting

Closeup of the brush head covered with foam dust

First panel is done, 1/3 of the sign is almost done

Cutting out more details of the first panel

Image of what the sign will look like

Moving along to the second panel

The second panel is coming along, as the background is now cut out

The leaf details are cut out

Video of the second panel - as it's being cut

Up close of the leaf details

The third panel is done, it just needs to be cut out from the backing

The whole sign is all cut out. It is 80" long. I need to glue it together and paint it

I am very pleased with how it turned out, I need to assmeble and paint it, as I finished cutting it, the day before I went back to college for sophomore year.