SKILL LEVEL intermediate
by Dremel ®
Tools & Accessories
11 1/2" Screws
23/4" x 2 1/2" x 14" Plywood Planks
23/4" x 2 1/2" x 23" Plywood Planks
13/4" x 32" x 19" Plywood Plank
150lb Concrete Mix
1Concrete Mixing Tub
1Large Wooden Address Numbers
Let's Get Started
To reduce the risk of injury user must read instruction manuals for all tools used in this project. Wear eye and respiratory protection. Use clamps to support work piece whenever practical.
Start by cutting wood that will be used to contain and mold the concrete sign during its drying process. Measure and mark lumber to the dimensions below. Mount the US500 Wood Cutting Wheel accessory onto your Dremel Ultra-Saw™ tool. Clamp the lumber and cut along your marks. Wooden Frame and Base Dimensions (2) 3/4" x 2 1/2" x 14" Plywood Planks (Frame Ends) (2) 3/4" x 2 1/2" x 23" Plywood Planks (Frame Sides) 3/4" x 32" x 19" Plywood Plank (Base)
Layout the frame components cut in Step 1 in a rectangular fashion with the two 14" end planks placed between the two longer 23" side planks. Drill 1 1/2" screws through the side planks into the edges of the end planks to create the frame for the concrete mold.
Mix the concrete that will form the body of the address sign. We found that a 50lb bag of concrete mix worked perfectly for the size of the frame created in Step 2. Please refer to the directions included with your concrete mix to determine the proper steps for mixing. As a reference, our final piece came out to 14" x 21" x 2 1/2" using this quantity of concrete.
Place the frame created in Step 2 onto the large 32" x 19" plywood base cut in Step 1. Pour the wet concrete mix onto the wooden base and into the frame. Level the poured concrete by taking a scrap piece of wood and running it across the length of the frame. We found that there was no need to secure the frame to the base but you may choose to do so if worried that the frame will move during the pouring/drying process.
Layout and lightly press the address sign numbers into the concrete mix so that they are arranged correctly and at the depth of your preference. We decided to purchase large painted wooden numbers for our sign from a nearby hardware store but they could also be made using your Ultra-Saw and other Dremel power tools. Allow time for the concrete to dry as instructed on the packaging of your concrete mix.
Now that the concrete is dry, use your drill with the same bit from Step 2 to remove the screws securing the frame of the concrete mold together. Remove the wooden frame to reveal the new concrete address sign.
To give the concrete address sign a finished look, make use of the Ultra-Saw's surface preparation capability. Mount the US410 Diamond Surface Prep Wheel onto your Ultra-Saw. Start the tool and move it in a circular motion making light passes along any course or un-even areas avoiding contact with the address numbers. If the address numbers became dirty during the creation process, repaint them as needed. Place the completed concrete address sign in your location of choice. We chose to display ours as a free-standing piece surrounded by flowers but you could also mount or secure it to your desired location for added stability.