Saving Face

Because of the thickness of this sign (3") and the material I have to cut it out of I had to extract 2 slices from the design using enroute. Below is a screen shot of the front view of the sign in Enroute.

In this shot the red rectangle represents the size of the plate,( material that I'm going to cut this out of), as you can see the face of the cow stands above the plate.
I made 2 slices with the first one being 2" thick and the remaining piece can cut out of a piece of 1" material.

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once slices are complete and toolpathed it's off to the Multicam (router).
Look Ma No Face!
This was a big file with all the textures etc. It took the router 7 hours to cut this piece. ( this is when you hope the power dosen't go out !)

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Both pieces ready to be glued together using "Gorilla Glue", a urethane glue that works well with the Urethane foam.

When all parts are cut I'm using my vac clamp, which is a giant bag that you suck all the air out of and the atmospheric pressure applys a tremendous amount of force which clamps everything in place. This is a great system for clamping odd shaped parts that you could not get conventional clamps on, and it creates equal pressure all over the parts.
This similar type of system (without the bag) is what is used to hold the parts on the router table when it's cuttting.
The other advantage to this type of clamping is thatthe Gorilla Glue expands as it cures and can really make a mess, The bag that holds the parts in place contains the expansion of the glue and makes for easier clean up of the glue line.

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Once again I ask should I do a video of glue drying?