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I'll repeat myself...It's a cheap laminate and this is what happens when you use cheap materials.
I am perplexed by these kind of posts
"I used cheap and it's not working"
Here is a thought.
Why not separate yourself from everyone else.
Use the best materials available,charge for it,make more...
We never clear coat gold leaf.It dulls the look.Only exception would be if it was done on a truck door or any other place where it could be abused.
Get the book "Gold leaf techniques" for more info.
One hour each piece at least after you figure in all the other time associated with it.
Why rout that out of plywood?
Looks like it's going to be a fragile piece
1/4" should be good enough.
Knowing how much something will expand and contract is important especially when joining dissimilar materials.
Most sign materials like acrylic come with a spec sheet that has all the physical properties that list expansion and contraction.
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