Last fall, our good friends at Workhorse approached us about helping them with a rebranding project for their client, Rock Creek Homes. Rock Creek Homes is a high-end home remodeling and construction company in the Washington, DC. Because of their appreciation for design, Rock Creek wanted a "real estate sign" that didn't suck. We brainstormed with Workhorse and came up with an idea to use a traditional Japanese wood preservation technique, Shou Sugi Ban. Shou Sugi Ban is a way of burning the surface of hardwoods so that they are naturally resistant to rot, insects, and water. Oh, and it looks amazingly beautiful.
Inspired by the Japanese technique, we chose to use traditional Japanese joinery to frame out the design of the sign. This made for a cohesive look to the sign, one that complimented the new logo and accentuated the luxury positioning of Rock Creek Homes.
Coffee in hand, I spun up the blade of the table saw quickly making sticks out of a bunch of cypress boards. Then I laminated the boards to form the legs of the sign.
Gluing up panels for the main sign board and the phone number board was a cinch. Armed with a pattern bit, a Bosch router, some double sided tape, and a baltic birch plywood template cut on our Epilog laser cutter, I cut the smooth curve for the main sign board with the router.
I used thru tenons, held in place by walnut dowels to keep everything firm. The tenons were a real pain to chisel by hand.
Then I filled some of the nasty looking knots with epoxy resin.
After a quick trip to Lowe's to pick up a handheld flamethrower and a propane tank, I terrorized my neighbors by cooking the sign in my driveway.
Next we carefully positioned the main sign boards in the laser, and slowly etched the wood. The laser pulses disintegrated the burned surface of the cypress, exposing the lighter color wood beneath.
Realizing I forgot chain and hangers, I drove back to Lowe's, grabbed the chain, and went through the same checkout line. The cashier gave me a weird look and I made a beeline back to the Jumbie workshop to paint the chain black, to keep it from standing out too much. From there, the sign came together nicely.
Rob, the owner of Rock Creek Homes, was totally amped on the sign.