Looking for Trouble

Removal of old graphics, redesigned with new translucent vinyl. Entire case repainted.

Twenty-five years ago, it was possible to make a modest living repainting old signs. I was able to repaint almost exclusively because fading walls and panels were so ubiquitous. I don’t do many today because vintage fixer-uppers are such a rarity. Nevertheless, the renovation and remodel mentality still has some practical applications and seems to have made a life-long impression on me. Occasionally, I come across a new business with an inherited acrylic-face sign structure that still has some potential to be reused. When I have an opportunity to think inside the box, it’s surprising how many different ways these familiar signs can be creatively refurbished.

The first selling point is to alert the client to the unrealized potential of what they already possess. The on-the-street sign salesman can take advantage of the situation because it is obvious that something has to be done with their obsolete sign structure. At the very least, the previous imagery will have to be covered up or removed. Finding some way to use existing parts has great potential and also happens to be the cheapest way to go. The installation cost of sliding in a compatible replacement panel will always be a fraction of the cost of building anything new. If a client wants an illuminated sign, there are some economical options that can make use of the frame and retainers. Furthermore, there are a number of ways to reuse the previous sign face itself, which may be a pleasant surprise for everyone.

Old graphics removed and panel flipped around with new translucent vinyl.

RE-ILLUMINATE
I have learned some important lessons when re-lettering existing white signs with new translucent vinyl. All vinyl removals are not created equal. Obviously, it is impossible to accurately assess how much work it will be without an extensive test. I have spent a half day with a helper and heat guns, and I’ve also removed 75 square feet of vinyl by myself in 15 minutes. There is an art to charging the right amount for this valuable recycling process. For the average job, I use a #16 mat cutting blade and a neat little hair dryer that starts when you squeeze it. I follow that up with straight citrus-based cleaner or Rapid Remover. It is important to completely clean off the adhesive remover before applying the new vinyl. Hopefully, there isn’t much of a ghost image left over, but sometimes it is necessary to deep clean the panel with a lot of time-consuming rubbing. At other times, I’ve been able to cleverly cover up some chronic blemishes with a new “all-over” design or background. If a white panel is really sun-tattooed, I’d consider using the back of the sign if that is practical. Light fading or yellowing rarely is bad enough to show through to the other side of the sign when illuminated.

Will work for food! Three Stone Hearth is a local community kitchen that serves delicious bulk meals. It is on a limited budget and wanted to do a large amount of trade. The original idea was to hang a banner over the old sign. Instead, I painted the background very economically with a mixture of 1 Shot and flattening paste. The graphics were hand-painted astonishingly quickly because of the rough lettering style.

The Village Dog inherited a huge blank yellow surface that was glued up from three pieces of acrylic. I painted over it all with an aged-looking off-white blend. The graphics are hand-lettered, but could have also been vinyl.

The Niroga Center rented its storefront and found it had a massive 5’ x 6’ box with no plastic left at all. It wanted a hand-painted sign and had no interest in an illuminated sign. The new panels are over-sized Alupanels decorated with Ronan Aquacoat.

REPLACE
There are a number of reasons for not reusing an old panel, such as baked on vinyl, a wrong color background, appliquéd letters or cracking. When replacement is optimal, I want to know what should be the appropriate material to use. I ask myself whether it should be acrylic or poly-carbonate, white or clear, pan-faced or flat.

Acrylic is cheaper and can be used as a 4’ x 8’ or smaller. For anything larger, poly-carbonate is usually my only option. Poly-carbonate comes in large sizes and can be up to 100 times stronger than acrylic, which makes it easy to drill, cut roughly or drop without cracking. On the question of white or clear, I determine whether the sign graphics will look better first-surface on white or second-surface reversed on clear. In general, white will work when stock vinyl is available in the right color. The final product will have a dull sheen because all translucent vinyl is low-sheen. The clear tends to be the better choice when prints or painted graphics are called for.

The second-surface option yields a nice, uniform high-gloss, which can be desirable. I’ve learned to check if the new plastic should be custom-formed. If the light-box is thin, it is likely that a pan-face is required to provide adequate separation between the bulbs and panel, so the light will diffuse properly. The formed pans can be ordered in white or clear, and I have found them reasonably priced at World Wide Sign Systems.

OPAQUE REUSE
Occasionally, I become involved in a project where the client is stuck with a legacy sign that could be expensive to deal with. If I find that they are unattached to a light-up sign, this can open up a few options. Why not offer them an economical deal that would have an opaque background? Perhaps the existing panel can be painted with oil-enamel or laminated with opaque vinyl. There also is a chance that a composite panel, such as Alupanel or DiBond, could fill in the space. These substrates can be attached, so they overlap the retainers, but it is much neater when they are able to slide into the existing holders. A big advantage of this method is that I can use paint, vinyl or even metallic finishes to create a one-of-a-kind presentation.

Reuse and recycle techniques have the potential to work up to the client’s budget in several creative ways. Often this strategy can work as a win-win for a low-budget prospect. It also is a decidedly ecological, if not green, strategy. If there is one knock on sign-making materials that can be difficult to counter — it is that they last too long because they degrade too slowly once they are retired. Why not turn this around by giving them a second life when appropriate? If the panel won’t work in place and needs to come down, don’t throw it away. I’ve found that old poly-carbonate and laminated panels can be used again to make hand-cut dimensional letters. I call that thinking in and out of the box at the same time.