Sign & Digital Graphics

March '20

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Page 24 of 185

S D G M A G . C O M • M A R C H 2 0 2 0 • 2 1 The metal parts were cut from 5052 plate aluminum ¼" thick, including a one-piece border. The letters and border were drilled from behind without going all the way through, and then tapped for threads using a bottom out tap and our "FlexArm" machine. Locally, we could only find construction-grade, two-inch-thick cedar boards, but they would have to do even though the grain was not really consistent from one board to the next. Each board would be trimmed down to about 4 ½" wide, but first the table saw was checked for true perpendicular cuts. The planks were ripped carefully, a little on each side so they would clamp up together in a tight fit. After ripping each board to the right width, their rough length was trimmed to exactly the right dimension. The sign was temporarily put together with clamps, and the border was put in place and mounting holes were marked by short, sharp studs in the backs of the metal. After placing the border perfectly, a pattern was thumb tacked to the sign for locating each letter perfectly.

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