How to Make the Perfect Wooden Layered Happy Birthday Sign

 Proxxon's scroll saw and bandsaw team up to make this layered happy birthday sign.

Here's list of supplies you'll need and the Proxxon tools I used:

• 6" x 11" blank up to ¾" thick for base
• 8" x 3" x ¼" blank for letters
• Acrylic paints
• Liquid wood glue
• Hanging hardware
• Base Sign and Happy Letters templates
• Proxxon Bandsaw MBS/EP
• Proxxon Bench Drill Press TMB 115
• Proxxon Scroll Saw
• Proxxon Delta Sander
• Proxxon Pensander PS 13
• MICROMOT Flexishaft 110/BF

Instructions:

1. Download and print the Sign Base and Happy Letters templates.
2. Mount the patterns on blanks. Cover one side of the blank with painter's tape. Mist the back side of the patterns with spray adhesive, and mount on the taped blank. The painter's tape made removal of the patterns easy without leaving any sticky residue. (Note: If you rearrange the letters, you probably can get them all on a smaller blank.)
   
   
   
3. Cut the exterior shapes on the bandsaw or scroll saw.
   
   
   
4. Use the drill press to drill pilot holes in the interior spaces for the scroll saw blade. Use a drill bit just large enough to accommodate the blade.
   
   
   
5. Sand exterior edges using the flexishaft mounted with a sanding disc.
   
   
   
6. Use the pen sander to sand interior edges and tight angles.
   
   
   
7. Paint the base and letters with your choice of acrylic paints. Set aside to dry.
   
   
   
8. Glue the letters to the sign base.
   
   
   
9. Celebrate!!
   

Carole