Plane Old Wood
 
We are doing a project this weekend with Ken Christie and his family. It is the YOU ARE NOW IN BEDFORD FALLS sign from It's a Wonderful Life. 
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I worked on a profile for the trim around the sign and come up with four.

Vote on the one you like the best.  Click on images to enlarge.
First I pulled the image from the movie into Sketch up and did a match to try to get the size. Ken estimated that the top of the sign was 6' high so I used that and calculated everything else with Sketch up. Ken found a font that was close but we had to stretch it in Photoshop to make it long enough. He then printed it out and cut out each letter to make a stencil.       

The sign ended up 8' wide by 7' high. It is ¾" plywood with western red cedar trim.
Laying out the stencil and painting the sign was a big job.

We had to glue up a block for the curved moldings and rough cut them on the band saw. 
We made a template of the curve the width of the molding and used a flush cut bit on the router table to clean it up. Since I was cutting against in some cases I needed to take light passes so I couldn't us the bearing so I made a little jig to hold to work against and moved the fence to adjust it.  
The legs are 4x4 pine but they were very warped so by the time I joined and planned them they were just over 3 x3. The post are mortise and tenon  into the foot. I added blocks to the ends of the feet so that it would stand better on uneven ground. (And I thought they looked cool.) To fasten it to the ground we drilled hole through the feet at a slight angle and made stakes from 18" galvanized rod to stake it to the ground.   

Here is the finished sign on location.