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Directional and informational signs aren't required to use tactile or Braille. The "Visual Characters" on the signs DO need to meet contrast, size requirements, etc.
Eastern Metal Supply carries 6' x 12' sheets of mill finish....not sure if painting is an option for you.
I think the largest they have pre-finished white is 5' x 10'.
You might try removing all of the pieces or taking it off the wall and looking for a manufacturers name. They typically have stickers on them somewhere indicating who made them.
If someone is going to grab the edge of a letter and pull on it, it will either bend (ACM) or break (thin acrylic). Either result will require a new letter. The ACM letter though would cause more of a injury concern if a letter were bent and poking out.
Nothing is vandal-proof obviously, so...
I would also vote for VHB tape and silicone for what you're doing.
I agree that it isn't the best choice of material - primarily because of peoples lack of common sense and inability to keep their hands off things. I would opt for acrylic with eased edges.
We have a 12 year old Staffordshire Bull Terrier that still acts like a puppy but is losing feeling in his rear legs (nerve damage). Projected to be paralyzed in both legs within 6-12 months. The vet said due to quality of life, most are then euthanized. He's survived three cancerous tumors so...
Rather than re-type it, I'll just copy and paste info I wrote in another thread:
Not all VHB tapes are recommended for vinyl. Vinyl contains plasticizer which can negatively affect the adhesion of VHB tape.
The only VHB tapes recommended for direct use on vinyl are: 4941, 4945 and 4991. Also...
Agreed with using overlay panels. Refurbishing those on site is borderline ridiculous. Make new panels slightly oversized to hide the existing and you'll finish in a fifth of the time and have a better, more stable product.
Lexel adheres better to acrylic and dries clearer than silicone. There's no such thing as an invisible adhesive though - there's always a chance you'll see portions of the adhesive since the letters are clear. You could use a few pieces of clear tape along with the Lexel, but again - you'll...
You could try Master Signs here in Dallas. They do nice work. No real need to pay for shipping from Ohio or Missouri....
The attached is completely painted, 2nd surface, no vinyl.
I would try low expanding spray foam (for doors and windows). It's much easier to control and can be applied more precisely. If you get any on the face of the letter, clean it with acetone before it dries.
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