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Shear is an important tool. Get a good one. I've had this Niagra 1911 model for 35 years. Still cuts nice. Bought at yard sale for $10. 4 men and a pickup truck to transport.
Wow what an opportunity. A building that heats itself in the winter. Leave the windows alone. Tell them to turn it into a tropical restaurant. Sell em palm trees.
Yup sign materials cost money. 4x8 sign foam $350.
If your just starting out you could stretch your design and cnc execution legs on some home depot rigid foam insulation.
It routes pretty clean and could be used for certain signs.
Latex printers are cheap. Just buy a new one. It will come with a warranty. Save yourself headaches down the road. If you don't buy new you will be back here asking for help with someone else's junk that they sold to you.
Don't worry about or search for cheaper materials to make your signs because cheap materials are harder to work with and the the cost of the materials should only be a fraction of what the sign sells for.
Why would you not want to make your signs from the best material available?
Just curious. Who is in charge at your shop and who is in charge of your stress management? Is it you or do you let your customers set the rules and call the shots?
These are the problems you run into when you are a replicator instead of being a creator. If you want to make signs from other people junk you just have to deal with it. In a perfect world you would get files that are perfect and setup so all you have to do is hit the print button.
In my shop it cost the customer more if they want to use their material. Think about it. Go to the customer and pick the sheet up. Order some red paint and rollers. Paint the board and hope it sticks and looks good.
A new sheet of red acm cost $75. I would happily spend $75 to not have to deal...
This happens if there is an outline on the letter. Do an experiment. Send something with an outline and the same graphic without and see if that's the problem.
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