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:toasting:Welcome from the frozen midwest.

:thumb:Low mist coolant can cause similar issues but from his description his mist coolant was working properly. I've been out of the router room so long I can't remember all the numbers but the harder the alloy the better for routing, you can actually see the difference... the good stuff will...

You can bump up the rpm if you want to but I don't think that's your problem. The only thing I can think of is the aluminum is too soft. I you didn't tell your supplier you were going to rout it they could have sold you 5051 or something that wasn't meant for routing. You need 2024 or some...

What's your feed rate, we cut .125 on our Sabre in one pass with a 25-30 feed rate.

Not sure I'm understanding, I think you're wanting a pan without a flange. The flange is the part that goes outward parallel to the face on a normal pan face. Problem would be getting the EXACT measurements, the big sign companies can waste a few pieces of plex until they get their molds set up...

Sounds like someone's trying to do their own maintenance, you wouldn't happen to own a motel would you or say a chinese restaurant? We have to clean up after guys like that all the time:banghead:, try to do their own work and then call us when they get it screwed up really bad.:frustrated:

Looks like it's time to get out the brushes and get to work. There's been a lot of artistic liberty taken with those fonts. Since you're doing several of them, could you do one by hand and "digitize" it, been a long time since I've had to do it that way but used to do it all the time especially...

I really hate to say this :banghead::banghead: but :banghead::banghead: Mosh was probably right. Looks like a flex face retrofit would be the simplest solution. If your really intent on a formed face... either Milliken or World Wide Sign Systems would probably do a pretty good job.

Also....:help

:banghead: Had one this week... this guy wanted a 30'x80' double sided billboard wrap. What really gave him away (besides the horrible english), he want them "hammed" with 4 grommets. I really don't see how people fall for this crap, using multiple cards for payment should have been a really big...

Just a thought, have you ever thought of using Ultra Board or similar product instead of Gatorfoam for interior applications? We've used it on several occasions and had good luck with it. It uses a polystyrene laminate instead of cardboard, vinyl sticks great.:thumb:

:Oops:We had it happen before when one of my guys installed a sample version of Flexi Sign and didn't tell me:frustrated:. Had to call Gerber and they told me that Flexi will hijack the driver used for their dongle. That's been 3 years ago but I believe uninstalling Flexi fixed it, can't...

That's a pretty sweet looking light table, great for lining prints up back to back for lighted faces:thumb:. When I was in production I preferred to work on a light table with a glass surface, easier to keep clean and then if you needed the light just flip the switch. But like you said, with the...

I usually have my light source coming from the upper left with a lower right shadow, the rule of thumb I was always taught is that we read from left to right. By putting the light source in the upper left, that draws your eye to the upper left first then to the right. Supposedly making it easier...

Time to break out the noodle pot. I make homemade chicken and noodles for the family get togethers, my grandmothers were my favorite this time of year:tongue:. After she pasted away I found her recipe and have been making them for family functions every since.... time for lunch, you guys are...

We've found that if you paint both sides it works just fine outside, we only use 1/2'' and 3/4'' for routed dimensional lettering anymore. I won't use bare PVC outside anymore, I just don't like the way it weathers, after a few years the edges get dark and dirty looking and seem to swell a...

:thumb:BECAUSE IT WAS THE CHEAPEST BID! Always educate your customer and let them make the choice. Of course some don't care about the hot spots and then it makes you look shoddy because you did it, which is why we don't... want crap?... go to our competitor.

:thumb: Most of the problems we experience with failure is due to expansion and contraction of the acrylic due to extreme heat and cold in exterior application. I don't think you need to over think it too much for interior applications. If the temp. is stable it shouldn't be a problem.:rolleyes:

:notworthy:Hey some of the rest of us may have noticed it but we expected nothing but the best from you (plus we weren't polite enough to think to say anything). Can't have no stinkin screw heads messing up a perfectly good sign. We stud, glue or screw from the back side, NEVER through the face...

Still not enough info here. How much experience do you have? Have you ever routed 1/2'' alum before? What size and kind of bit? How many passes? We have no idea of your level of experience.:help