Sign for Zephyr Brewing Co.

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Project by KnotCurser posted 12-26-2013 02:24 PM 1925 views 2 times favorited 8 comments Add to Favorites Watch

The owner of Zephyr Brewing Company, in Denver Colorado, hired me to create a sign for his brewery/pub.

He wanted it to look a bit weathered and rustic, so I used some reclaimed, distressed oak planks and glued up some random sizes. I left a rough edge on the top and bottom and didn’t even trim the sides. The rusted nail holes were a bonus!

Before starting on the carving, I sealed the surface entirely with about four coats of brush-on lacquer.

After designing on the computer and having my CNC Router do it’s job, I used Rit dye in the carving area and wiped the excess off after a few minutes. The lacquer I applied earlier kept the oak surface from staining.

Then I applied a few coats of spray-on lacquer and knocked down the final coat with steel wool to get a matte finish.

Overall dimensions are around 15×21 inches.



-- Robert Rhoades WoodWorks / Email: [email protected] /

8 comments so far

View stefang's profile


16705 posts in 3748 days

#1 posted 12-26-2013 02:37 PM

Looks great Bob!

-- Mike, an American living in Norway.

View degoose's profile


7255 posts in 3769 days

#2 posted 12-26-2013 08:15 PM

Looks like a bought one… well done…

-- Don't drink and use power tools @

View Roger's profile


21006 posts in 3218 days

#3 posted 12-26-2013 11:23 PM

Looks good. How is the beer?

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. [email protected]

View KnotCurser's profile


2032 posts in 3483 days

#4 posted 12-27-2013 01:42 AM


No idea for two small reasons….......

1) I am in Maryland – the brewery is in Denver.
2) The brewery hasn’t opened yet.



-- Robert Rhoades WoodWorks / Email: [email protected] /

View oldnovice's profile


7487 posts in 3782 days

#5 posted 12-27-2013 01:46 AM

Bob, I like the sign, the description of the process, and the fact you used dye!

Could you have used any other color?
How did you mix the dye?

-- "I never met a board I didn't like!"

View Pete Jansen's profile

Pete Jansen

250 posts in 3336 days

#6 posted 12-27-2013 01:49 AM

That’s awesome. Don’t have access to my cnc router as it’s at the ex’s house. I love doing stuff like you just did. Keep it up.


-- Lovin' sawdust in beautiful Fort Collins, Colorado

View scrollingmom's profile


1196 posts in 2878 days

#7 posted 12-30-2013 12:08 AM

That looks great. I love the idea of making it with what ever was around.

-- Kelly, Allen,KS

View KnotCurser's profile


2032 posts in 3483 days

#8 posted 04-25-2014 11:38 AM


I have used a number of different colors of Rit dyes in the past.

For this sign, I used it straight from the bottle – undiluted! Just make sure you are wearing gloves as, naturally, it stains fingers for days!!!!

If you wish to have a lighter shade, just mix a small amount with water – easy done!


-- Robert Rhoades WoodWorks / Email: [email protected] /

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