John Byrd gives a Georgia apothecary a makeover.

By John Byrd

John Byrd is proprietor of John Byrd Design (Ball Ground, GA).

After more than 15 years of serving the community, the Ball Ground (GA) Pharmacy was moving into a brand new location and needed a new sign package. After having solicited proposals from several area sign companies, the store’s management selected my bid because they preferred my idea.

The building’s new architecture reflects early 20th Century architecture, so my design fits that style. I created the original design using Corel Corp. CorelDraw™ and, to build a full-size, workable file, I transferred it to CADlink Technology Corp. Signlab 7.1. I presented this design to the client with pricing options, which covered fabrication options that ranged from flat to fully dimensional. Fortunately, they chose 3-D fabrication that features a 2-ft.-tall mortar and pestle and fabricated scroll work. I knew I would have a fun week building this sign.

Tips and tricks

al; -webkit-background-origin: initial; background-color: initial; font-family: arial; font-size: 1.2em; font-weight: normal; left: 0px; line-height: 1.5em; margin-top: 1.7em; margin-right: 0px; margin-bottom: 1.7em; margin-left: 0px; overflow-x: hidden; overflow-y: hidden; text-decoration: none; top: 0px; color: #333333; background-position: initial initial; padding: 0px; border: initial none initial;">Because the store’s grand re-opening was quickly approaching, I put this job on the fast track. Because I don’t own a CNC router, I built this sign as I always have -- by hand -- with knowledge, tricks and techniques developed through 30 years of commercial signmaking (and, sometimes, scratching my head and asking, “What if...?” to ponder solutions).

Using my old, but reliable, Gerber Scientific Products IV-B plotter with a Cadlink card, I developed pounce patterns (yes, I still use them). I pounced the pattern onto 15-lb. Duna HDU board and traced it with a #2 pencil before cutting it with my bench-top Delta bandsaw and handheld Bosch jigsaw.

To fabricate the mortar and pestle, I first glued together two stacks of HDU half-circles, which looked like a wedding cake, with Gorilla Glue. After the adhesive cured overnight, I formed the angled shape with my Ryobi belt sander. I rounded the top, bottom and center pieces with my handheld router and ½-in.-diameter, round-over bit.

To remove the HDU residue, I blasted the panel with water from the hose – don’t waste your time with the air compressor; I think the static electricity that forms makes bursts of air less effective -- and then glued together the final assembly. To form the pestle, I used a 4-in. x 4-ft., post finial I’d saved. I chucked it into my drill press and sanded the cuts until I’d fashioned the end of a pestle.

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