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the larger the letter, the more it will expand...if they are tight in the 'F-track' they will pucker/warp...
FWIW looking at F-track, I would hate to service letters made with it.
1st surface print (face of acrylic/polycarb) -- regular density print on translucent material (so it looks correct in the daytime)
2nd surface print (reverse side of acrylic/polycarb) -- regular density mirrored print on clear (so that it bumps color density when backlit and looks correct/not...
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