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Zinc Sandblast Stencils Rick Glawson wrote this step-by-step process after researching the Rawson and Evans patent. Rick had found one of the orignal zinc stencils on a visit to Chicago about 15 years ago, then pieced together the steps. Since Rawson and Evans did not have rubber sandblast stencil, they developed this process, apparently used extensively on repeat signs or designs. The next step, not mentioned here, would be to coat out a piece of glass with asphaltum, press the zinc stencil down, then blast away the exposed glass—frosting it in the process. From that point, warm hide glue was carefully poured into the frosted areas. The asphaltum helped push back any glue that might have overlapped onto the protected areas. Special thanks to Danny Baronian for saving Rick's notes and forwarding them to us here. 1: Obtain zinc, preferably .032 - .062. 2: Apply frisket cut design (or plotter cut vinyl), and remove negative area of frisket. 3: Coat entire area with asphaltum, coating the backside also. Let dry for 20 – 40 minutes. (Mike's note: you could also "cut in" the backgrond area with a brush and asphaltum. More than likely, this is the way Rawson and Evans did it since they didn't have a plotter or fisket resist) 4: Remove positive area of frisket, exposing clean zinc. 5: Pour a mixture of 1/2 water and 1/2 muriatic acid (28%) into plastic tray. 6: Immerse zinc into solution. "DON’T BREATHE THE FUMES". 7: Let sit in solution for 20 – 25 minutes. 8: Wash asphaltum off with paint thinner. 9: Solder wires across the design or letters to hold centers in place.    The image below is from the US Patent Office illustrating one of Rawson & Evans patents using the process above.