A friend commissioned me to make a sign for his father. Since it was going to be used outdoors, I made it out of ipe, a brazilian mahogany that will stand up to the elements.
After deciding upon a font, I printed out this full scale version and used it to transfer the design to the board.
After transferring the marks with a knife, I traced them with a sharpie for better visibility and began to remove material using a trim router.
Removing the material is a slow process, but not one you can rush.
After removing all the material and cleaning it up a bit with a chisel and some sandpaper, it was ready to deliver.