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graystone church sign made of foam graystone church sign made of foam pieces glued together graystone church sign sanding the seams graystone church sign 10 foot circle graystone church sign routed for frame graystone church sign routing matched frame graystone church sign glued frame graystone church sign applied foam over frame graystone church sign filled routed area with foam graystone church sign trimmed excess foam away graystone church sign sealed the back of the sign
graystone church sign finished the back graystone church sign painted letter silver graystone church sign silver letters are 2 inches thick graystone church sign painted the face black graystone church sign painted the sides black graystone church sign finished the sign graystone church sign time to take the sign to the church
graystone church sign in a large moving van
graystone church sign it was a big sign
graystone church sign arrived safely at the church graystone church sign had a lift delivered for the install
graystone church sign used a pattern to install brackets graystone church sign brackets are installed graystone church sign used the lift to raise the sign graystone church sign sat on the brackets
graystone church sign install
graystone church sign attaching the sign to the brackets
graystone church sign reaching behind the sign to drill
graystone church sign moving the lift
graystone church sign adjusting the lift graystone church sign still working graystone church sign did I mention it was freezing
graystone church sign and I'm scared of heights graystone church sign final inspection graystone church sign my wife hates this hat
graystone church sign show how it's away from the wall
graystone church sign shows the hidden brackets
graystone church sign shows the shadow on the wall
graystone church sign finished graystone church sign  has a floating effect graystone church building numbers graystone church plastic building numbers graystone church building number close up view
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Graystone Church Sign was a unique job for many reasons. First when discussing the sign options I realised that the walls were built with plywood and then a stone overlay was applied for a finished look. This is all very fine and looks great, but nothing can securely attach to the stones, the could come loose, that leaves just the plywood to hold up the sign... the size of the sign needed, 10' in this application, creates a large amount of weight. This wall was'nt designed to hold that kind of weight. And rather than tear down and rebuild ( very costly ) I suggested I design and manufactured this sign out of Foam! Yep! styrofoam, this reduced the weight to the point it's not even a factor now. Understanding the look they wanted, I was able to make the sign using 6" thick styrofoam, created a 10' circle, then added a 2" thick styrofoam created a 9' circle with the "g" cut out. Naturally becauce of the size, I had to build this in pieces, arranging and gluing joints for the maximun strength and support. And because of the fragile nature of styrofoam I could'nt even rest my hand on it while I was working because it would dent so easy as seen in some photos. And if that was'nt enough I could'nt reach the center of the sign I only have a 4' reach and the center was 5', so I had to work the center while the sign was on it's side. Once the seams were finished a hardening material was applied to give the styrofoam a durable outer shell, this was then finished and painted to the signs design specifications. During this process a mounting system needed to be fabricated to securely attach to the sign, and to the Church wall. I had to get the sign up there too, that's aprox.30' in the air. Weight being a factor, I had a light weight steel frame manufactured just for this sign. As the pictures show I routed out the sign to get the frame inside the sign, this for strength. Removing the stone from where the brackets should bolt, we bolted the recieving mounts to the wall. Using a scissor lift to lift the sign we attached the sign. All brackets are hidden from view and the sign seems to float on the wall above the entrance. This job took over 2 month, I thank everyone for their patience, with it I kept the weight down to 80 lbs. for the sign and frame included. And created them a Great looking sign, it should serve them well.
Graystone Church
1551 Ozora Road, Loganville, Georgia