I love this project! This is an inexpensive and easy way to add serious curb appeal to your home. I have made quite a few of these signs for friends and neighbors, framed and unframed, and they always look great on any style house. The design of the numbers give them a modern look, and adding the frame can soften them up a bit.
What You'll Need:
(1) 3.5" X 6ft. Cedar Fence Post
If you are framing your sign: (1) 1X2 Poplar board (I use these)
Miter Saw or Circular Saw
Brad Nailer
Drill
1" Brad nails
Drill bits
5" Modern House Numbers (I use these)
Caulk
Wood glue
If you are framing your sign: Exterior paint in your preferred color
Instructions:
Step 1: Cut down your fence post. Using your miter saw or circular saw cut the post down into the number of pieces you will need to make your sign. The width of each piece and the number of pieces will depend on the orientation of your sign and the amount of numbers in the address. Make sure the boards are cut EXACTLY the same size.
First, let's talk width:
*Assuming you are using the same numbers that I am, which are 5" tall and average about 3.5" wide
Vertical Sign: For this orientation, the boards will be positioned horizontally. You want to make sure the spacing is the same on all sides of the numbers, so it looks professionally made. I have decided that I want my spacing to be 1.25" on all sides. Since the numbers are about 3.5" wide, I will need to cut my boards at 6", so there will be 1.25" on either side of the number (1.25+3.5+1.25) = 6
Horizontal Sign: For this orientation, the boards will be positioned vertically. This one is easy, because all of the numbers are exactly 5" tall. For this sign, I decided to make the spacing 1" on top, bottom, and on the sides; therefore, I cut my boards 7" wide. (1"+5"+1")=7"
Now, let's talk about how many boards you need to cut:
*This depends on how many numbers you have in your address, and how much spacing you want between each number. Keep in mind, the Cedar fence post I'm using is 3.5" wide.
Vertical sign with 3 numbers: 6 horizontal boards (making it 21" tall)
Vertical sign with 4 numbers: 8 horizontal boards
Horizontal sign with 3 numbers: 4 Vertical boards (making it 14" wide)
Step 2: Using the rest of the Cedar fence post, make a backer board spanning the length of all the boards put together. Let's use my vertical sign with three numbers as an example. When I put the 6 boards together vertically, the result is 21" tall. Cut a piece of the Cedar fence post to 21"
Step 3: Glue the boards down onto the backer board, making sure they are perfectly straight and even. Reinforce them from the front of the sign with brad nails down the center (2 in each board) Try to put the nails in places that will be covered by a number.
Step 4: Apply a generous coat of the Tung Oil to the front of the sign and let it dry overnight.
Step 5: Apply a generous coat of the Tung Oil to the back of the sign and let it dry overnight.
*If you are not framing your sign, skip to step 10*
Step 6: Time to make the frame! I created a modern-looking frame by just overlapping the boards on each side vs joining the sides with two boards cut at 45 degree angles. First, you'll need to know that a 1x2 board is really only a .75 X 1.5 board. <I'm not sure why they do that.> Cut 4 pieces .75" longer than the sides of the sign. For example, the vertical sign with 3 numbers is 6" X 21", so I am going to cut (2) 6.75" and (2) 21.75" boards.
Step 7: Sand the 1X2 boards, paint them with exterior paint and let them dry.
Step 8: Place the sign, face-up, on a flat surface, so you can nail the frame on straight. The frame will be 1/4" taller than the cedar sign when they are all lying flat on the table. Place the first board against the sign with one side perfectly flush with the sign and the other side extended .75" from the sign. Nail that board to the sign. ;Attach another board to the adjacent side with (2) brad nails. Continue doing this all the way around the sign.
Step 9: Caulk the nail holes and the seams at the corners, and touch up the paint.
Step 10 : Apply the Spar Urethane to both sides of the cedar (not the frame) and let them dry overnight.
Step 11: Time to add the numbers! I have a little trick I use to help me get this right. I put a border of painter's tape around the perimeter of the sign, the same width as the space I originally decided upon when I cut the boards. I do this to help me determine the correct placement of the numbers before drilling holes in the wood. At this point, we are 4 days into this project, so I don't want to mess it up! On this horizontal sign, I decided that I wanted 1" spacing between the numbers and the edge of the sign, so that is where I placed my tape. As you can see, the numbers fit exactly within that spacing. Now I just need to play with the spacing between the numbers themselves.
Step 12: Attach the numbers to the sign. Now that you have the numbers exactly where you want them, drill pilot holes into the sign through the holes where the screws are going to go. Then add the screws. These numbers come with plastic spacers that go between the number and the wood, so the numbers are raised.
Step 13: Add the hanging hardware. I'm using a Keyhole to hang my sign, and they can be tricky. Since I am hanging this sign on a brick wall, and using a Tapcon screw to do so, I will need to drill a hole under the keyhole, so the screw can fit. Tapcon screws have large heads on them that won't slide between the wood and the keyhole. If you are using a nail or regular screw to hang your sign, you can just attach the Keyholes using the manufacturer's directions.
Here's how I attached mine. I used one keyhole at the top of the vertical sign and two keyholes on each side of the horizontal sign.
Screw in the top screw only.
Color in the hole with a pen
Swing the bottom around, so the keyhole that you traced with the pen is exposed
Using a 3/8" drill bit, carefully drill out the traced area. BE SURE NOT TO GO THROUGH THE FRONT OF THE SIGN! The hole just needs to be large enough for the head of the screw to easily slide up and down behind the keyhole hanger. If you chip the wood a little, that's ok. It will be covered by the keyhole hanger.
Clean out the sawdust from the hole and screw down the bottom of the keyhole hanger.
All set! I hope you enjoyed this project. Please post pictures in the comments of your own address sign!