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Justin has something to offer for most skill levels. I'd say it's worth alone in what you get by way of concessions just to take the class. I never bothered with the certification, but I thought if/when you did pass you ended right on carwraps.net as an Avery trained wrap provider...
You can try a liquid adhesion promotor, get the sheets corona treated or you may be able to skimp by with just taking a propane torch to the surface of the acrylic right before printing.
I found the 3M to be more brown than black personally. My chip chain swatch of the Avery looks richer than the older roll of 3M I used on my roof. The sun +1yr of horizontal exposure has made it even more brown.
I build the tolerances in.
You using adhesive backed extrusion to connect the sign header to your acrylic blades on top of the unit? Is this just a friction fit or are you dropping glue/solvent into joints for adhesion?
I'd be looking at die cutting for 800 pcs, but really you need to provide more info. There's plenty of vendors on here with print & cut systems that may be interested.
If the margins are good and you can manage the install I don't see the problem. Looks like fun personally, but I'm sure an initial hurdle will be how long you make the pieces so you can handle the weight of the pieces up in the air and for an 8hr day. Brands Imaging in Philly did a pretty big...
We screen or print direct on 2,3,4,5 & 6mm Coro all the time, but it is manufactured with more UV inhibitors in it. I've seen them last with printing on the 5-6mm stuff for upwards of 8yrs. They do not get 100% sun exposure. They are outdoors 365 days a year though.
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