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sebago_signworks
12-08-2008, 07:08 PM
I need to make a 48" x 96" push through sign face. Im not sure how to do so... here is what I thought up so far. Start with a .50" White Acrylic, and an .080 sheet of aluminum. Boar out the acrylic (except where the copy goes) to 3/16", then route th .040 (knok out where the copy goes) Place the .040 over the acrylic, glue, fasten centers on, install. Whats your thoughts?

letterman7
12-10-2008, 10:44 AM
That's pretty much what a standard sign shop would do. Don't hog the entire acrylic face, though. Isolate the copy or even letter by letter and rout it down. I used to drill holes in the acrylic flange, push them through the aluminum (.080 at minimum), mark the holes and then tack weld studs to the back of the aluminum panel so I could secure the acrylic with nuts and washers. A generous dose of polyurethane caulk around the acrylic perimeter will help hold it in place.

wcsg
12-15-2008, 10:46 PM
There is a couple of different ways you can do this. How many letters? Are they large?

You can do this with the flange, without the flange. Use mechanical fastners with a flange or use 3M VHB tape and silicone.

I think you can probably get away without a flange if using 1/2" letters. Inline your letters .030 smaller than what you cut the alum. You can cut 1/8" white #7328 acrylic panels and VHB them to the back of the Alum and clear silicone the edges too. Once the 3M VHB tape is cure you can use #16 Weld-On and adhere the rears of the 1/2" clear acrylic letters to the white panels.

The only time I usually cut flanges with my letters is when using 3/4" material which is a lot heavier and usually for larger letters.

Not sure what your design is but I would use clear acrylic for the letters with 3M translucent vinyl (my pref is leaving a 1/16" inline on the vinyl exposing a little clear acrylic for that silver lining appearance, 1/2" white is thick and harder for light to penetrate. Save the white for the rear. For the use of flanged acrylic letters use 3M 70% diffuser film on the rear.

Here's a recent job did
http://www.westcoastsignco.com/modules/gallery/albums/album02/PLSportsSide_Shot.jpg

Some useful links
http://www.thesignsyndicate.com/forums/index.php?showtopic=1936

http://www.thesignsyndicate.com/forums/index.php?showtopic=1206

http://www.thesignsyndicate.com/forums/index.php?showtopic=694

http://www.thesignsyndicate.com/forums/index.php?showtopic=748

http://www.thesignsyndicate.com/forums/index.php?showtopic=445

sebago_signworks
12-17-2008, 02:27 PM
Erick,

Wow, looks great. I really appreciate your advice as its really helpful. In this case the letters are white, do you suggest using clear, with a white overlay? Do you mind if I ask what the going rate per sq. ft. is on this. I do not want to underbid. Thank you greatly for your help, Merry Christmas

wcsg
12-17-2008, 02:38 PM
What is this sign backlit with? Fluorescent lamps, Neon, LED? For best light transfusion on 1/2" material I have to say go clear with translucent white on the face of the letters as well as either diffuser film on the rear of 1/8" white acrylic.

Not really sure what it is you're building or the scope of work being performed so it's hard to give you pricing.

sebago_signworks
12-17-2008, 10:21 PM
Its an old 48" x 96" Cabinet that we are giving a facelift. It is lit by Flourescent, its an 12" Cabinet. I am not positve what you mean by "well as either diffuser film on the rear of 1/8" white acrylic". I have seen this for sale before but I do not know the purpose of it. We are not an electric sign shop so we are green to this. Again, thank you, you hae given me lots to chew on.