Rooster Teeth asked us to make an RTX Sign!
Hey, I’m Jamie and I’m Jay and today we’re gonna make a giant RTX sign So Jamie what is RTX? RTX is rooster teeth’s annual Expo here in Austin. About 60,000 fans come together for a weekend of panels, and autograph signings, and parties. It’s a whole lot of fun. So 60,000 people are gonna see the sign that we made? Hell yeah. Nice! so Rooster Teeth commissioned us to make the sign for their main booth here at the expo where fans get to come and take pictures with the roosterteeth staff, cast and crew, Let’s play youtubers and other awesome people and we said absolutely we want to do that. That sounds really fun And then they said we only have a week to do it So we figured we’re up to the challenge though So we took it on we’re gonna rewind the clock and show you how we did it Believe it or not We had a plan and that was to use the x-carve cnc machine to cut out all these letters and basically put them all together again. We wanted it to be hollow so it’s not too heavy and we needed a sturdy base so that nobody could knock it over We got the RTX logo from the folks at rooster teeth and from there we could start breaking it down into pieces and figuring out how we were actually going to build this Our x-carve has a max cutting area of about 30 and a half inches so we based the first R slash T on that and everything else was split up so that it could all be strategically fit onto smaller pieces The first step was to start breaking down these seven sheets of 3/4 inch plywood They’re super heavy and they’re really big and they don’t fit on our table saw at full size So we have to rip off the first part manually Wow Battery is dead. 🙁 Like immediately a bunch of stuff went wrong the battery died in the saw and we switched over to the jigsaw and that wouldn’t cut because we had a dull blade so we switched the blade that finally worked so we were able to rip that but then it wouldn’t cut on the table saw either so we realized we had the wrong blade in the table saw so we swapped that and finally it worked. The first step here was to break down three full sheets into a bunch of pieces and then each of those got ripped in half and boom. With the first batch of material ready to go we headed over to the computer and pulled up the Easel software where we could start setting up our cuts for The X Carve. if you haven’t used this software before I highly recommend checking it out You actually don’t even need a CNC machine to use it. You can log in for free and try it out Check the link in the description basically What you can do is upload your design and then you can set up all the stuff like the size and material you use How deep you want it to cut what type of material it is. Super cool you can then set the size of the router bit you’re gonna use so that it knows exactly what the cuts gonna look like as Well as giving you the ability to simulate the cut and figure out how long it’s gonna take As you can see this one’s gonna take two hours and we have a ton of them to do so Let’s get going We secured it down to the table using the blue tape method and then there was a little bit of bow in the board Which kind of pulled the corner up but we figured we’d see what happens Easel was pretty spot on with its estimate It did take just over two hours to complete this cut. this plywood we’re using is not the best material So there was some bow to it and using the blue tape method didn’t end up working very well So we went with clamps throughout the rest of the pieces. Other than that though. Everything worked really well The first one that we pulled off I was really careful with this because I wasn’t sure how flimsy it was gonna be I thought it might break but this was actually really strong Then about 16 hours later, we had a whole bunch more and we could start putting this thing together The process for putting these together was crazy easy because we used the x-carve. They were exactly the same So all we had to do is put some glue on the face and use some clamps to line them up really carefully after that We used a brad nailer to start working away around the edges to nail the corners and pretty much any span that was over about Six inches got a nail, too because things were going too well our nail gun broke and Totally died. Total loss. So we had to go pick up a new one. And of course getting a new tool Isn’t that bad. Always nice. But it did kind of stink to have to completely stop in the middle of this very tight time line to go to the store But hey, you know stuff happens, so we got the whole thing together And for the very top piece who did the same technique, but we couldn’t clamp it because there was no inside layer So we just had to be really careful to make sure it was lined up and then we just went all the way around with The Brad nails. it was so cool at this point because it actually started to look like a real thing When you’re doing through cuts on the x-carve it leaves these little tabs so that the pieces stay together while they’re cutting and those come off real easy with a block plane or You could sand them off, too So there’s one last thing to do on this big R before I pass it on to Jaimie and that’s to fix this little Missing strip in the top right here. on one of the CNC cuts. I accidentally had the starting point at the wrong position So it went off the top of the board and missed about a half inch of the top of this So all we have to do is rip a piece of plywood Glue it in there and then flush it up and then it’ll be ready to finish I grabbed some of the waste from one of the R cuts and just cut off the top piece of it Sent it through the planer to get it down to the thickness I wanted and then added some glue in the groove and spread it around put the thing in the thing and yeah That was pretty easy. We trimmed off the ends and then a few swipes with a hand plane and it’s like there was never an issue. awesome. So while all this is happening, we had a second set of shapes going on the X-Carve. that big vacuum hose There is our home brew solution to try to do some basic dust collection for the X-Carve But it doesn’t work very well and we definitely need an upgrade. We made a lot of dust on this project. Many many many many hours later. We had all the pieces cut and we put them together the same way All right! Because this is end-grain We’re not really sure how well it’s gonna take the paint and there’s a whole bunch of little holes and voids in there So what we’re gonna do is a little test. We’re gonna try some spackle put it on there See if that gives us a nicer surface to work with before applying the spackle I wanted to use a block plan to get rid of all the big nubbins then I did a pass with the orbital sander using 180 grit sandpaper, I Applied a super thin layer of spackle to the wood making sure to fill in all the big gaps This stuff dries really quick. So I had to make sure it worked fast Since this is just a test and we’re gonna go over with four passes later. It didn’t need to be perfect So this turned out pretty well now we’re gonna go while Jamie kept doing that I was reinforcing the inside of some of these parts with some extra pieces that made it so that when we actually screwed them together, We would be screwing into more than just end grain since that wouldn’t be very strong Since this is on the inside and no one would ever see it We just took some of the waste boards cut them into little squares and then glued and nailed them into each piece We only need to put them in the places where that was gonna screw into the base on the bottom and then anywhere it would attach to another piece So I just put these two pieces together for the first time just to kind of check things out see how things are coming together and immediately notice that there’s an entire layer missing from the other half of the T and Well, here it is So that’s cool…forgot to put that on… And yeah, I blame the heat. It’s currently 97 degrees in here Turns out I did that in a few places So we made that fix and we’ll have to spackle it later. And then we finally got to see it start coming together. Nice, huh? Now that we actually had something that was starting to look like something we moved on to the next piece of the puzzle Which was the bottom of the X. So we broke down the next sheet of plywood and then went over to the x-carve machine and started cutting it out At this point we had this whole process dialed in and it was super easy We just got everything set up let the Machine run for a long time and got all the pieces cut many hours later We had all the pieces we need we put the bottom of the X together and then we repeated the same process for the top Of the X which you’ll see shortly We figured we’d skip over the epic tale of how we assembled this very simple plywood box Which is the base because it’s pretty simple. It’s a plywood box With the base built though. We could finally start putting this whole thing together We had all of the pieces made So the first step was to attach the very bottom of the X with the sort of other bottom of the X That little triangle at the bottom Sticks up a little so it creates a nook and we could slide the top part in have it stay there And from there we could start clamping and adjusting things and getting it all together This is the part where things could have gone horribly wrong, but it all lined up really. Well, man. We were very excited With everything centred on the base We started sinking the screws into the bottom With a love tap here and there to make sure it’s nice and square and straight and then we just started working our way down Sinking all the screws we needed Occasionally we would stop for a minute to double check that everything was still nice and straight and square But we ended up having really no problems at all. I’m all lined up nicely we sunk at least two of these screws into each connection and some of them got three and then Short while later we had a thing Next up was what was my favorite part? We finally get to put the front faceplate on and have a really starting to look good. So I got the faceplate kind of clamped on to the letters and we’re gonna trace out the outline so we can cut it out But the middle of the board is a little bit bowed and it’s not quite lining up perfectly I don’t have a way to clamp that tighter. So we’re just gonna give it a shot and something goes wrong We’ll deal with it then With the board clamped on we took a pencil and traced out the outlines of all of these shapes There was like a million cuts to do at this point So I started with the circular saw it just cut all the straight lines Oh good and then moved on to the jigsaw to cut out the more complex shapes this took a little longer than I expected Just because there were so many cuts but it really wasn’t a big deal We finished it up brought it over and clamped it on to the rest of the piece Making sure everything was nice and lined up and that there was at least a little bit of overhang we then simply took the brad nailer and Brad nailed it Here I used my ultimate strength muscle power and lowered it by myself Awesome, and then we flush trimmed all of that overhanging using flush trim router bits This helps us to basically make it flush with the outside but because there was so much overhang because of that bow and the board this was a Really long process that took like 2 hours to get through the whole thing It paid off though, cuz everything was super flush and perfect. And then Jamie could come in the spackle and really finish that up nicely Lastly there was the mouse cursor part of the Rtx logo Which got cut out on the x-carve and Brad nailed on and from there? There was just a lot of sanding to really polish up the outside make it nice and smooth and get it ready for paint We’re using our makeshift paint booth outside Which is basically just a big canopy And we went with spray paint using a white primer for the front and a black primer to the back and the sides We painted the front first and then masked off all the white and then painted the black on the sides and back in the end it took three cans of white for the front four cans of black for the sides and back and then two cans of A satin clear coat. Alright, we made it here to RTX. We just delivered the sign We were definitely skeptical about getting this thing done on time, but we did it and it looks so freakin cool I really hope you guys liked it. Let’s take a look Hey thanks for watching. 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