Dimensional letters are an important component of my business. They may stand-alone on a wall or be integrated into a more deluxe sign panel. Part of the finesse of a successful dimensional letter job is a smooth installation. There are myriad of ways to install dimensional letters and it can be difficult to find an approach that is consistently reliable, no matter what the situation. Profits can be won or lost depending on the progress of small details. I know I’ve arrived at the proper solution when the installation goes so smoothly that it is hard to imagine how I could have had a problem in the past. There is no single “right way” to attach letters, but you’ll know it when it happens. The following tips describe some efficient methods I’ve found to help make installations easy and profitable.

 

VHB tape installations were unreliable and expensive in the past, but both of these issues have been rectified. I’ve started to use the new Gemini Inc. system of pre-installed VHB with good results. The VHB letters shown were installed using a computer-generated pounce pattern for an interior flush mount. (See Photo 1) The pattern chalk doesn’t show at a distance, but next time I’ll bring a can of compressed air to see if that can help clean up the line dots. If the installation surface is smooth, it can be very helpful to put down a vinyl layer as a pattern for a flush mount with tape—or quick-drying glue in an emergency. (See Photo 2)  

 

I urge everyone to think about the dust clean-up before the drilling starts. In this case, I taped up a paper dust catcher that is easily rolled up and thrown away, which is a better solution than leaving dust behind or lugging around a vacuum cleaner. (See Photo 3) For exterior jobs, it is best to blow off everything with an air-compressor, which can evacuate dust inside the hole and out. If this is not possible, hopefully the surface can at least be swept off and wiped before the letters are attached. Occasionally, dust will contrast with a dark (usually black), porous wall in such a way that it can’t be cleaned well. When feasible, I paint over the whole area before I install the letters. (See Photos 4, 5) 

 

For interior letters, I center the pattern by folding in the middle and then use a level, as opposed to measuring from the floor or from the ceiling. For heavy or post-relief interior letters, I drill all of the holes with an exact placement and a light touch. If I hit something, I stop and mark the hole. (See Photo 6) I don’t want to accidently widen the piercing by overworking a stubborn metal stud or risk glancing off an obstacle that would make a mess. I bring clippers or bolt-cutters so I can create a stubby post just long enough to stick into the ½" drywall. It is helpful to have different types of glue on hand. (See Photo 7) Sometimes it is possible to drill the holes with a tight fit so that the letter’s posts bind with very little, if any, adhesive. Wood glue can be a good choice when the holes are tight and just a dab will help lock into the dusty drywall sub-surface. It can be easier to have the hole slightly larger so that all of the letters drop in uniformly. I use clear Lexel adhesive for just about every other situation, especially when the glue will be on the outside of the wall and may show, as it would for a post relief. The Lexel clear silicone glue takes 24 hours to hold weight, so it is always necessary to have an initial hold of a post, or a second quick drying glue or tape in conjunction with the slower drying material.

 

It is important to consider how the adhesive actually contacts the wall. The strongest bond is a flush post mount with glue all over the back of the letters. Gel glues don’t do much inside of a dusty wall, no matter how carefully one cleans out the holes. Construction epoxy would work better, but it is messy and difficult to use. This means that the glue is generally only holding to a small area outside of the hole. Post mounts have less area to grab and it is conceivable that a careless installation could be exceedingly weak and vulnerable to weather. (See Photos 8-11) 

 

I’ve had success hand-making letters and then manufacturing a custom mounting system. For HDU, I set each letter upside down on a drill press, and then drill a deep hole that is the exact width of Gemini’s threaded aluminum posts. This way I can screw in the post with a small amount of West Systems two-part epoxy and the posts will stay straight and tight. Once the letters are complete, I press them into a plotted paper pattern over a piece of carpet or cardboard. Then I mark the indentations to serve as a drill guide. For the God’s Story letters, I glued Gemini glue pads to the back of hand-cut 6mm Alupanel Lite. (See Photo 12) The letters are thin, but the pads offset the letters by about 3/8" so they look more substantial.

 

I like to through-bolt letters when possible. (See Photo 13) This makes the letters secure at ground level and there is no glue dry time to contend with. However, it can be a bit time-consuming to drill all of the holes and tighten from the back. This method also requires some type of frame or backing thickness to allow for the fasteners. I like the look of a thicker sign with post collars, but it does drive the cost up. I’ve found it necessary to try new combinations that might be easier to sell. In order to reduce costs, I’ve recently used the 6mm Alupanel alone for the background, and then used Gemini pre-installed glue blocks and pads (See Photo 14). The Green Moto sign sold for about $1,000 installed, which wasn’t too bad for a “cheap” sign. The client wanted something nice for a low price and the final result looks pretty sharp.

 

The bottom line is, don’t be deterred by installation obstacles. A little bit of ingenuity and experimentation can go a long way toward making dimensional letter installations successful and rewarding. Don’t let tricky installations diminish the significant profits and possibilities of dimensional letters. Be creative, familiarize yourself with a variety of tools and products, get lots of practice and don’t be afraid to try something new that just might work.