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I would have to say we are using ours for about 10 -12 yrs lost count, we run less because we upgraded to a newer one. There are different brands and styles depending your production. If I had to guess the mileage on ours is closer to 50k hrs+. Software issues is probably the critical thing on...
Are you trying to stick the hat or u channel inside the sq. tube to have some wiggle room to attach inside columns? I don't get it, or is it wall mount and the bracket claps the frame? just weld the plate to the frame. The engineers are not sign makers they don't know what's right from wrong.
Why don't you try doing 500 pcs. from setup, print, trim and cut to figure labor and your materials. I'm sure if someone walks in the door you are not going to sell him a decal for $$$?
Route the panel like you normally would, try to avoid the copy if possible. We glue a flat piece of .125 alum to create a lip and them glue the other half to it. you can leave the visible seem or put a few tack and bondo the face.
Like Tim said, use the wide mouth pliers to stretch from one side to the other no need for template screw top then bottom but only from the middle section do the same left to right then stretch and work the screws outward towards the ends.
I think your section detail might be confusing a bit, you have your retainer first, then your painted white perf metal not vinyl followed by the white acrylic in front of your rgb leds.
Does the customer want metal perf or is that to prolong the life of the face vs using perf vinyl? I think your idea is doable and will work. I think the fab is trying to get out of making retainers for the letters and just using trimcap. They have thin aluminum perf you can use for the faces.
First see if you can change your setting on the program you are using and GaSouthpaw is right, we typically run at 18000 rpm and 60-100 inches / min. speed. The bit you are using might be an issue too if it's too cheap it wont cut clean. We only use Belin / Onsrud.
How thick are you thinking of making it? if you are not planning to illuminate it. Do a plywood backing so you can screw the coil aluminum to the side and you don't have to bend/brake a flange, back in the days people used plywood with an aluminum face Laminators Inc. still makes it Omega board.
If not try this I have used it before and is just like spray paint, but HD has a lot of paint assortment...
Custom Paint | Custom Color Paint | Custom Color Spray Paint | Myperfectcolor.com
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