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If money is concern. The least expensive way would be.
Skin over it with ACM.
Decorate that however you want.
Do yourself a favor and put an angle on the back of the top. VHB, screws, glue or whatever is appropriate. Drop it on there and collect.
It's not rocket science. Briteline window perf is notorious for this. You are doing a disservice, on all fronts, to yourself and your customers by using the cheap stuff. Buy the good stuff. Problem solved.
Reach out to UL directly. If your a shop making signs that use electric and doing it properly It's not that hard.
There is no "cheap way" around getting listed. You follow their rules and pay the bill they give you.
This is what you get when you sub out work. One bubble can make a customer unhappy. Who can install vinyl with no bubbles? Think your gonna find a vinyl wizard that can do flawless work. This is why I refuse to install stickers for other companies.
You don't usually machine a spoil board. It's usually a piece of coro or cardboard.
You surface your machine bed.
If it's MDF if it wants to be thicker so you resurface many times.
On the bright side now you know how to make a potato chip.
Keep lookin around. I'm sure you will find someone cheaper than than the vendors who provide quality signs.
Maybe try to sell them on superior quality and service?
We make a fair share of banners and rarely put a hem in them. Grommets yes.
Unless it's going to have a wind load on why bother? It does not make it look any better or that much stronger.
The banner celebrating Grandmas 75th birthday that's going to be zip tied to a fence for 3 hours does not...
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