When you have a laser, your family tends to ask for things, especially if the brother in question is getting married. I was commissioned to build some lettering for the head table. Glamour shots first:
I wanted to make the letters more… 3 dimensional than a single layer of material. But when I calculated how many sheets of material I would have to buy (my brother’s design was not exactly optimized for a sheet of PG maple ply), I started thinking about what else I could put in the middle to make things a little less expensive. I am lucky enough to work at a place with ready access to cardboard, and thanks to the GF, I also can copy the same item without worrying about all the sanding that normally comes with woodwork. (yes, there is sandpaper in the picture, but it was for a different project, i promise)
I ended up with 6 layers of 1/4" cardboard, sandwiched between layers of PG medium draftboard (great stuff). The downfall of cardboard (at least in this project) are the voids around the edges. Since I was traveling for work, used the free hotel newspaper to wrap the outline to hide the voids after the glue up, then used a razor to trim the edges and layered on the draftboard.
Running out of time before the wedding, I rigged up the letters to hang in front of a heater in the garage after I spray painted a couple coats of a white primer, then a sparkly gold
The newspaper was not the best choice, I would have gone with something a little thicker, maybe at least a second layer of newspaper. The spray paint was a little heavy in places and there was some bubbling. I take back what I said about sandpaper.
However, everything looked fantastic for the big day and the happy couple was exactly that!