Nice looking work Joe!

When you do these kinds of signs with pockets for letters of a different material than the sign background, do you just make them fit tight or do you have to leave room for expansion/contraction?

Has it ever been a problem for you with this method?

I've seen electric sign faces where they cut the plastic too big and then in the summer it bulges in or out like a pillow. Or worse, in the Chicago winters a piece cut too small can actually fall out of the frame.