View as slide show 1  First, the boards are planed to thickness. I like to make signs at least 1-1/2 inches thick to guard against splitting and warping. 5  An adhesive paper mask is applied to the face of the sign. The pattern is transferred to this paper. 2  The boards are glued with waterproof adhesive, and clamped together. 6  The lettering and motif are hand-carved, THROUGH the paper mask, using traditional double-bevel chisels. The carved areas are then sealed. 3  The sign is shaped, the edge is fluted by router if required, and the surface is sanded. This sign is made of cherry wood. 7  The lettering is either painted in colours which contrast with the sign background, or gold leaf is applied to the carved letter "channels" 4  The stain and several coats of varnish are applied. Yes, the final finish is applied BEFORE the lettering or motif is carved. 8  The painted or gilt lettering is outlined in black, and the sign is hung in place (or mounted on clips if required), using stainless steel hardware.