Step 2 Measure 225mm from 1 end of timber offcut and drill a pilot hole through timber. Drive a nail through pilot hole so it is sticking out the other side by about 20mm. Line up point of nail with centre of rectangle on plywood and hammer in. Rest a pencil on plywood at 1 end of timber. Move timber around to scribe an arc outside both sides of rectangle. Reserve timber.
Step 3 Using power saw, cut along straight lines on plywood, ensuring saw blade is on waste side of your lines. Stop saw where straight lines meet curve of arc, then use jigsaw to cut along curved lines.
Step 4 Place cut-out sign on remaining plywood, trace around edges and cut a second sign as you did the first. On second sign, draw a line 15mm in from edge all around. Cut 15mm off reserved timber and scribe inner arc. On inside of this line, drill 10mm holes, insert your jigsaw blade and cut around line. This will create a raised border for sign.
Step 5 On a computer, type out letters of chosen word and print. Cut them out and space them along your sign to make sure you are happy with their proportions. Trace letters on plywood offcuts and use jigsaw to cut them out. Tip, with letters with holes in their middles (such as an ‘O’), drill a hole first to provide access for your jigsaw.
STEP 6 Sand edges of sign, border and letters. Start with a coarse sandpaper to remove saw blade marks, then move on to a finer grit in order to get a smooth finish.
STEP 7 Paint body of sign in white, and letters and border in black. Let dry.
Step 8 Apply construction adhesive to underside of border, place it on top of sign body and press into place. Secure with nails.
Step 9 Space letters out on sign evenly, using straightedge to ensure they are aligned. Working with 1 letter at a time, glue and nail letters to sign.
Step 10 Place sign on wall and screw through top to secure. Ensure level using spirit level, then screw through bottom of sign.