Build a sturdy, eye-catching wooden sandwich board for your shop in a weekend! This guide simplifies the process with clear steps, tool recommendations, and safety tips, making it perfect for beginners. You’ll create a professional-looking sign that’s easy to update and built to last.
Hey there, fellow DIYers and shop owners! Jack Shaffer here, your go-to guy for all things woodworking and nail-gun related. Ever walk past a shop with a fantastic handmade sign and think, “Man, I wish I could do that!”? Well, you absolutely can! Today, we’re diving into a project that’s both super practical and incredibly rewarding: building your very own wooden sandwich board sign. These classic A-frame signs are brilliant for grabbing attention outside your store, announcing specials, or just sharing a friendly message. They’re way more charming than a flimsy plastic sign, and building one yourself is easier than you might think. We’ll break it all down, nice and simple, so you can get that sign up and drawing in customers in no time. Let’s get building!
Table of Contents
Getting Started: What You’ll Need
Before we start cutting wood, let’s make sure you’ve got everything you need. Think of this as your pre-flight checklist. Having all your materials and tools ready to go makes the whole building process smooth and enjoyable. We’re aiming for simplicity here, so you won’t need a whole workshop full of fancy gear. Most of these items should be readily available at your local hardware store.
Materials List
Here’s a breakdown of the wood and other bits and bobs you’ll need:
- Plywood: For the sign faces. A 4’x8′ sheet of 1/2 inch or 5/8 inch exterior-grade plywood is perfect.
- Dimensional Lumber: For the frame. We’ll use 1×4 lumber. You’ll need about 20-24 feet in total, depending on your desired sign size. Pine is a good, budget-friendly choice.
- Hinges: Two sturdy, exterior-grade hinges (around 3-4 inches) to connect the two sides of your board.
- Screws: Exterior wood screws. 1 1/4 inch screws are good for joining the frame parts, and 2 to 2 1/2 inch screws for attaching the plywood to the frame. Using galvanized or coated screws will prevent rust.
- Wood Glue: Exterior-grade wood glue adds extra strength to your joints.
- Sandpaper: Medium (120-grit) and fine (220-grit) grit sandpaper for a smooth finish.
- Primer and Paint/Stain: Exterior-grade primer and paint or stain to protect your sign from the weather and make it look sharp. Chose colors that match your shop’s brand!
- Optional: Chain or Rope: A short length of chain or sturdy rope to limit how far the sandwich board opens.
Tool List
Don’t worry if you don’t have every single tool. Some steps can be adapted.
- Measuring Tape: Essential for accurate measurements.
- Pencil: For marking your cuts.
- Saw: A circular saw is ideal for cutting plywood and lumber. A miter saw is great for clean, angled cuts on the frame, but a hand saw with a miter box can also work. If you’re not comfortable with power saws, many lumber yards can cut your wood to size for a small fee.
- Drill/Driver: For pre-drilling holes and driving screws. A drill with various drill bits is crucial.
- Clamps: Helpful for holding pieces together while glue dries or while you’re screwing them.
- Safety Gear: Safety glasses are non-negotiable. Hearing protection is also a good idea when using power saws. Gloves can prevent splinters.
- Orbital Sander (Optional): Makes sanding much faster and easier than by hand.
- Paint Brushes/Rollers: For applying primer and paint.
Designing Your Sandwich Board
Let’s talk dimensions. A common and practical size for a sandwich board is around 24 inches wide by 36 inches tall for each side. This gives you enough space to write your message without being too cumbersome to move.
Here’s a simple plan for that size:
| Component | Dimensions | Quantity |
|---|---|---|
| Plywood Sign Face | 24″ x 36″ | 2 pieces |
| Side Frame Pieces (Long) | 36″ | 4 pieces (1×4 lumber) |
| Top/Bottom Frame Pieces (Short) | 21″ (24″ minus the width of two 1x4s: 24″ – 3″ = 21″) | 4 pieces (1×4 lumber) |
| Optional: Spacers/Cleats (for chain) | 3-4″ | 2 pieces (1×4 lumber) |
This plan creates a sign face that is 24 inches wide. The width of the frame is calculated by taking the desired sign width (24 inches) and subtracting the thickness of the two side frame pieces. A standard 1×4 is actually 3/4 inch thick, so 24″ – (2 x 3/4″) = 22.5″. Wait, let’s re-evaluate the frame calculation: If the plywood is 24″ wide, and the frame goes around it, the shorter pieces will be 24″ – (2 3/4″) = 22.5″. Let’s adjust.
Corrected Frame Calculation:
| Component | Dimensions | Quantity |
|---|---|---|
| Plywood Sign Face | 24″ x 36″ | 2 pieces |
| Frame Side Pieces | 36″ | 4 pieces (1×4 lumber) |
| Frame Top/Bottom Pieces | 22.5″ (24″ overall width – 3/4″ for left frame piece – 3/4″ for right frame piece) | 4 pieces (1×4 lumber) |
| Optional: Chain Stops | 4″ | 2 pieces (1×4 lumber) |
So, for the frame, you’ll cut four pieces at 36 inches for the sides, and four pieces at 22.5 inches for the top and bottom. This makes a clean frame that perfectly fits your 24-inch wide plywood sheets.
If you want a different size, just adjust the plywood dimensions and recalculate the frame pieces accordingly. Remember, the shorter frame pieces will always be the total desired width minus twice the thickness of your lumber (for a 1×4, that’s 1.5 inches total).
Step-by-Step Build Guide
Alright, let’s get our hands dirty! This is where the magic happens. We’ll go through each step methodically.
Step 1: Cut Your Wood
Accuracy here pays off later. Measure twice, cut once!
- Cut the Plywood: If you bought a full 4’x8′ sheet, you’ll need to cut it down to two 24″ x 36″ pieces. A circular saw with a straight edge guide will give you nice, clean cuts.
- Cut the Frame Pieces:
- Cut two of the 1x4s to 36 inches long. These are your first two side pieces.
- Cut two more 1x4s to 36 inches long. These are the other two side pieces.
- Cut four 1x4s to 22.5 inches long. These are your top and bottom frame pieces.
- Cut Optional Chain Stops: Cut two small pieces of 1×4, about 4 inches long.
Step 2: Assemble the Frames
We’re building two identical frames, one for each side of your sign.
- Layout: Take two 36-inch pieces and two 22.5-inch pieces. Lay them out to form a rectangle. The 22.5-inch pieces should fit between* the 36-inch pieces. This creates a strong frame.
- Glue and Screw: Apply a bead of exterior wood glue to the ends of the 22.5-inch pieces where they will meet the 36-inch pieces.
- Pre-drill: Pre-drill pilot holes through the outside of the 36-inch pieces into the ends of the 22.5-inch pieces. This prevents the wood from splitting. Use a drill bit slightly smaller than your screw diameter.
- Fasten: Drive two 1 1/4 inch exterior wood screws into each corner. Make sure the frame is square before the glue sets. A speed square is your best friend here.
- Repeat: Build the second identical frame using the remaining four pieces of 1×4.
Step 3: Attach the Plywood Faces
This is where your sign starts to look like a sign!
- Position Plywood: Take one of your 24″ x 36″ plywood pieces and place it onto one of the assembled frames. The edges of the plywood should be flush with the outside edges of the frame.
- Glue and Fasten: Apply a small amount of wood glue along the edges of the frame where the plywood will sit.
- Pre-drill and Screw: Pre-drill holes through the plywood into the frame below. Space them out about every 6-8 inches around the perimeter. Use your 2 to 2 1/2 inch exterior wood screws. Make sure the screw heads sink slightly below the surface of the plywood without going all the way through.
- Repeat: Attach the second plywood sheet to the other frame.
Step 4: Join the Two Sides
Now we connect the two completed panels to form the A-frame.
- Position: Lay one of the sign panels flat on your work surface, plywood side up. Stand the second panel up and position it next to the first one, so the two frames are touching along one of the 36-inch sides.
- Attach Hinges: Place your two exterior hinges along the touching 36-inch edges. Space them out evenly – one near the top and one near the bottom. Ensure the hinges are flush with the outside edges of the frame.
- Pre-drill and Screw: Pre-drill pilot holes for your hinge screws. Then, attach the hinges to both panels using the screws provided with the hinges or shorter wood screws.
- Test the Hinge: Carefully stand up your sign. It should now fold open and closed like an A-frame.
Step 5: Add the Chain Stops (Optional but Recommended)
This prevents your sign from opening too wide and potentially falling over.
- Position: With the sandwich board open to a comfortable angle (often around 90-100 degrees), decide where you want the chain or rope to attach. Drill pilot holes into the inside face of the top 22.5-inch frame piece on each side.
- Attach Stops: Use wood glue and 1 1/4 inch screws to attach your 4-inch 1×4 “stops” to these pilot holes.
- Measure and Attach Chain/Rope: Measure the distance between the two stops. Cut a length of sturdy chain or rope that is slightly shorter than this measurement. This will give you a nice, stable angle when the board is open. Attach the ends of the chain or rope securely to the stops using eye screws or by drilling holes and threading the rope through.
Step 6: Sanding and Finishing
This step is crucial for both looks and durability.
- Sand Everything: Thoroughly sand all the wooden surfaces. Start with 120-grit sandpaper to smooth out any rough spots or tool marks, then follow up with 220-grit for a silky-smooth finish. Pay extra attention to the edges and corners.
- Clean Off Dust: Wipe down the entire sign with a tack cloth or damp rag to remove all sanding dust.
- Prime: Apply a coat of exterior-grade primer to all surfaces. This helps your paint adhere better and provides an extra layer of protection against moisture. Let it dry completely according to the manufacturer’s instructions.
- Paint or Stain: Apply two coats of your chosen exterior paint or stain. Make sure to get into all the nooks and crannies. Let each coat dry thoroughly before applying the next.
- Seal (Optional): For maximum protection, especially if using stain or lighter paint colors, consider a clear exterior sealant.
And there you have it! Your very own custom-built wooden sandwich board is ready to go!
Safety First, Always!
Working with tools, especially power tools, comes with inherent risks. Following safe practices isn’t just a good idea; it’s essential for a successful project and for you to be able to build more awesome things in the future!
Always wear your safety glasses when cutting, drilling, or sanding. They protect your eyes from flying debris. If you’re using a loud saw, slip on some hearing protection too. Make sure your work area is well-lit and free of clutter. Always keep your fingers away from saw blades and drill bits. Before you plug in any power tool, double-check that the cord isn’t damaged. And if you’re ever unsure about how to use a tool, don’t guess – ask for help or consult the tool’s manual. You can find great resources on tool safety from organizations like the Occupational Safety and Health Administration (OSHA).
Alternatives and Customizations
This basic design is just the starting point! You can easily adapt it to suit your needs and style.
- Size: Feel free to make it bigger or smaller. Just remember to adjust your lumber and plywood dimensions accordingly.
- Wood Type: While pine is budget-friendly, you could use cedar or redwood for even greater weather resistance, though these will be more expensive.
- Aesthetics:
- Decorative Trim: Add some thin decorative trim pieces around the edges of the plywood for a more finished look.
- Chalkboard Paint: Consider painting one or both sides with actual chalkboard paint. This is perfect for businesses that change their specials daily.
- Weather Vane/Topper: If you’re feeling ambitious, you could add a decorative topper or even a small, functional weather vane to the top of one side.
- Stenciled Graphics: Use stencils to add your shop’s logo or other graphics to the sign face before sealing.
- Leg Braces: For extra stability, especially on windy days, you could add simple leg braces that fold out from the back of the frame.
Frequently Asked Questions (FAQ)
Here are some common questions beginner woodworkers have about building a sandwich board.
Q1: What kind of wood is best for an outdoor sign?
For outdoor signs, you want wood that can withstand moisture and weather. Exterior-grade plywood is excellent for the sign faces. For the frame, pine is a common and affordable choice when properly sealed with primer and exterior paint or stain. For longer-lasting projects, consider cedar or redwood, though they are more expensive.
Q2: How do I make my sandwich board last longer?
The key to longevity is proper finishing. Always use exterior-grade primer and paint or stain. Ensure all surfaces are