Is it worth making this in-house?

[tulsagraphics]

I need to get (or make) a new sign face for this customer, but I haven't messed with trim cap installations before. I assume it's the same method as channel letters (doesn't seem too difficult).

I guess my real concern is making sure the thing actually fits.

- Are faces usually the exact size of the return? Dimensions are 96" x 24".
- What's a good substrate for this? Maybe a .150 polycarb?

Note: I used to refer these types of jobs to one of the local sign fab shops, but they've all closed down (nearest shops are about 60-70 miles away). Is it worth cutting my teeth on this kind of work? Or better to sub it out, sight unseen?

 

[MikePro]

polycarb should be fine, for me its actually ideal on larger faces.
yes its the same as an acrylic letter face ....EXCEPT you cannot use the regular channel letter weld-on glue for acrylics as it won't bond to the polycarbonate.
we use the weld-on 58 two-part polyurethane adhesive.

and the face is typically cut slightly larger than the returns, for looser-fit. the jewelite will cinch on, but you can't bow it out if its too tight.
i'm usually a ~.090" offset from the channel letter returns.

 

[tulsagraphics]

polycarb should be fine, for me its actually ideal on larger faces.
yes its the same as an acrylic letter face ....EXCEPT you cannot use the regular channel letter weld-on glue for acrylics as it won't bond to the polycarbonate.
we use the weld-on 58 two-part polyurethane adhesive.

and the face is typically cut slightly larger than the returns, for looser-fit. the jewelite will cinch on, but you can't bow it out if its too tight.
i'm usually a ~.090" offset from the channel letter returns.

Ah! Good to know. Thanks for the tips!

 

[Johnny Best]

Do it yourself, You will know how to do it next time it comes up since the other shop is closed up.

 

[weyandsign]

Use 3/16" acrylic and make it 1/8" bigger than the return.

 

[Bobby H]

Lexan (polycarbonate) is more flexible. If it isn't secured really good to the return it will be likely to blow off (just like the previous face). With the existing channel cloud shape having radius corners it might be necessary to get a face area pattern from the existing aluminum return. Or just take really good field measurements. Otherwise the new trim-capped face won't fit precisely.