When I first started making
signs I drew and painted them by hand. One of my first projects was for my late Aunt Delores, back when I was in high school in the early 1980's. She had a small (but really good) burger joint in New Mexico. The project involved a fairly large, non-lighted building
sign (plywood on a metal frame) and some hand-painted window graphics. I drew some thumbnail sketches and then refined them into scale drawings and interpolated them to the full size surfaces using a grid system. I was trying to follow some of the same methods as mural artists I had seen in a documentary.
Image enlarging projectors can be pretty handy for some projects, but it's critical to get the image thrown just right to minimize keystone distortion. A couple of my co-workers do a lot of hand-painted mural work and still use a projector to lay down a lot of the basic line work. When I first started at my workplace we still had a working projector and I used on a good number of projects during the early to mid 1990's.
During college I did a few odd jobs for a
sign shop in Staten Island to make some extra money (my class schedule was too busy for a regular full time or part time job). Most of those projects were hand-painted. Later I worked part time for a camera and
computer store in Manhattan helping create a bunch of their print ad work. I had to use a photostat camera and other tools to build up camera-ready ads using the same analog paste-up methods as old newspaper production. It's mind-numbing "fun" doing things like hand-cutting spot color plates out of amberlith with an X-acto knife or gluing various thing to a full size ad board with rubber cement.