Custom Aluminum Sign Fabrication for Gordy’s Surf Shack in Fontana, WI

When Gordy’s Marine needed to replace the aging wood sign at its Surf Shack in Fontana, Wisconsin, they called RC Portable Welding & Fabrication for a custom solution. As a repeat customer, Gordy’s knew we could take their existing sign and recreate the look using materials better suited for the new design.

The goal was to build a two-sided sign that kept the recognizable Gordy’s Surf Shack appearance while reducing unnecessary weight. We recommended aluminum and handled the project from the initial design through fabrication, powder coating, assembly, and delivery.

Replacing an Aging Wood Sign

Gordy’s contacted us because the existing Surf Shack sign was made from wood and had reached the point where it needed to be replaced. They brought us the old sign so we could use it as a reference for the new design.

Because the replacement needed to be two-sided, weight was an important consideration. We recommended building the new sign from aluminum rather than recreating it in wood. Aluminum allowed us to make a lighter sign while still creating the layered, custom look Gordy’s wanted.

Once we had a direction for the project, we created a design proof for the customer to review before any fabrication began.

From Design Proof to Custom Fabrication

Our custom fabrication process starts with understanding what the customer wants the finished piece to look like. For this project, the original Surf Shack sign gave us a clear reference point. After preparing the new design, we sent Gordy’s a proof for approval. Once they gave us the go-ahead, fabrication started the following day.

We used our CNC plasma table to cut the custom sign components, along with a hydraulic shear, punch press, and other shop tools to prepare the pieces for assembly. We then powder-coated the sign with a candy apple red interior piece and white outer pieces, creating the bold red-and-white appearance seen in the finished sign.

After the powder coating was complete, we assembled the two-sided sign and prepared it for delivery.

A Three-Day Turnaround From Fabrication to Delivery

From the start of fabrication to delivery, the project took about three days. Once finished, we delivered the new sign to Gordy’s office in Fontana.

The completed aluminum sign kept the character of the original Surf Shack sign while replacing the worn wood construction with a custom-fabricated design made specifically for the location.

Most importantly, the owner was extremely happy with the finished result.

Custom Metal Fabrication for One-of-a-Kind Projects

Not every fabrication project starts with a detailed drawing or a brand-new concept. Sometimes a customer already has something they like and simply needs a better way to recreate it.

At RC Portable Welding & Fabrication, we can work from an existing piece, customer idea, or custom design to develop a practical fabrication plan. From signs and specialty metalwork to commercial, residential, and industrial projects, our Elkhorn shop has the equipment to take a project from concept through finished fabrication.

Have a custom metal project in mind? Contact RC Portable Welding & Fabrication to discuss your idea and request a quote.