A friend asked me about making a sign as a present for his brother. He wants it as a late wedding present and he requested for the name to be the 'main attraction' but to somehow incorporate fireworks into the background. Reason was that the actual wedding ceremony in India was accompanied by fireworks....
After a few iterations we settled on the design below and I believe me met our goals. Hope he likes it as much as I do (he has yet to see the actual piece and pick it up).
The sign is about 24x8in and uses Maple on Walnut and includes a Danish Oil finish. The letters stand about 3/8in proud of the 3/4in Walnut board.
That is really awesome. I have mixed feelings about seeing being able to see the inset maple in some of the firework contours and I still can't decide if I love that aspect of it or not. Part of me is like "cool!, you can see that it's not just glued to the face" and then another part of me feels like I'm seeing part of the sign's underwear. ;-). It is a beautiful piece.
What kind of clearance dimension are you using for that inlay between the letter and the relief?
good observation though! I admit I didn't think about that aspect until I actually noticed it when I went to glue the letters in place. I am a little like you: Not sure about thumbs up or down.
Bottom line: Customer came by last night and thought it was 'really fantastic'..... enough said :-)
Re clearance: I tried a couple different pocket allowances and don't remember now if I went with 0.009 or 0.01 in. I cut the letters first and then started with an allowance I kind of knew was going to be tight. After trying the fit, I ran the tool path again with a bigger allowance and I think I nailed it on the third pass. Didn't take too much time as I had selected the 'use clearance tool' option for the toolpath and so, making the pocket slightly bigger, I only ran the final path (1/8 EM) again. Not the clearance path (1/4EM).