Here is my latest LED channel letter project that I just recently completed.
Two things unique about this project than my norm.
1) it's illuminated by LED's
2) The faces are done by products by Sculpt Nouveau, a local metal paint and patina maker.
This job was not made to meet my expectations as constraints of time were really pushed. There were aspects I wish I would have had time to do and original design by another sign compnay, such as make the letter faces to meet returns without separation or gap, texture the returns as well as the smaller dimensional letters. Paint the fasteners which you can see inside the clear tubing for stand-offs.
One thing I did change from specs was the paint job, which originall called out for a vertical fade across the "Solare" faces from light copper to dark using matthews paint system. I wanted to experiment using the Sculpt Nouveau system which greatly matches the interior of the restaurant and more of a raw and rustic look wanted by the owners.
I wish the building exterior paint could better go with the sign, lol.
Now to the LED's. I contacted Marko of YYZ and followed through with a promise I would use his in my next LED job I had coming, that was over a year ago today. The choice of LED's was perfect for this application, the letter stroke is much to small for neon or any other light source. Marko's very awesome to work with, I know he was very busy traveling and meeting other aspects of his work but still managed time to answer all my questions and offer suggestions, it went greatly appreciated! I sent him a .dxf file and he spaced out the LED's by letter and suggested spacing, so all I had to do was follow his provided layout pattern.
Cutting out the aluminum faces from the CNC
[img]http://www.thesignsyndicate.com/misc...re/solare1.JPG[/img]
Sculpt Nouveau textured paint and sponge I used for creating raised and textures on my faces
[img]http://www.thesignsyndicate.com/misc...re/solare2.JPG[/img]
Simple application and ready to spread across each face
[img]http://www.thesignsyndicate.com/misc...re/solare3.JPG[/img]
I spread around using my finger and then Sponging time!
[img]http://www.thesignsyndicate.com/misc...re/solare4.JPG[/img]
Drying time, it dries very fast, 15-20 minutes and ready to work more in if needed. After it dried I sanded the faces down so I had a some what flat surface with low spots for the patina's to sink into.
[img]http://www.thesignsyndicate.com/misc...re/solare5.JPG[/img]
The little bottle is the Liver Of Sulfur patina which is a hard rock you have to mix with water.
The can is for UV protection.
I gave all letters 2-3 coats by brush, but on the last coat as the letters were wet I applied the patina by spraying it on generously with a water mister, letting it dry with the paint for 8 minutes. I then washed the patina away lightly, lightly using a hose. With this patina I achieved a brown or bronze appearance with the copper. The Patina is a hard rock that need to be dissolved in water, but you have to use this quick because the water will dissolve it and the effect will not exist. This patina has to be used fast.
The UV laquor I used later after final coats. I used very small multiple light coats. I used too much at first and paint peeled up on my dimensional letters, lucky those and not the channel letters.
[img]http://www.thesignsyndicate.com/misc...re/solare6.JPG[/img]
The final finish on the faces. This is where I wish I had the time to texture the returns as well, but in a way, maybe not.
[img]http://www.thesignsyndicate.com/misc...re/solare7.JPG[/img]
The Halo.
I'm not sure if I did the rear backing right for diffusing the pinpoint LED lighting using polycarb with a simulated etched glass or frosted film. Maybe next time I'll try to put the LED's on the backing facing in and use the reflection of the flat white pan of the letters. I got a wierd shard glass appearance, but after looking at the night wall appearance I think it worked out good. With the type style it sork of gave a "fire appearance" with the orange so I think it was fitting.
[img]http://www.thesignsyndicate.com/misc...re/solare8.JPG[/img]
LED layout.
[img]http://www.thesignsyndicate.com/misc...re/solare9.JPG[/img]
The day shot of both signs
[img]http://www.thesignsyndicate.com/misc...e/solare10.JPG[/img]
A close shot
[img]http://www.thesignsyndicate.com/misc...e/solare11.JPG[/img]
Though I did not get a chance to do everything for this job I would have liked to, I still had fun with this project. This is one of those "Just get it up , whatever you have to do" type rush projects with the press and dinner comprised of local large business owners and the Mayor coming for a dinner
I really like the result of the orange color LED's and the textured simulated aged copper finish.
I took a bunch and out of those this one is the most accurate of the bunch. I'm using the under canopy light to help me in judging the true brightness of the sign and this one seems to portray it well.
I have to say in all honesty these 1/2 watt module LED's worked quite well.
[img]http://thesignsyndicate.com/miscstuf.../solarefin.JPG[/img]