Using a palm router we carved the design. We used a profile bit that we got from here: http://www.makeawoodsign.com/shop/index.php?route=...

The profile bit was used for all the detailed areas. Around and in between the letters, around the skull design and also the outer edges. To remove the bulk we used a 60 degree v groove bit. Just using a random pattern and being careful not to touch the detailed areas we removed the bulk. We carved around 1/4" deep but a little deeper if possible would be better. Using a brush we removed any sharp pieces and loose saw dust. The brush works really well in all the hills and valleys that we carved away.

The edge of the sign got a scalloped edge. We did that with a bearing guided shamfer bit. Edging it into the the side and then repeating it all along the edge. Each plunge meets up to the next one. Take your time and its quite easy to do by eye.