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Hmm. How do you going to service that machine if it brakes? Looks like it slides out to the side. if that is the case put all flat sides first with removable access panels. than you need to make round corner jig and use heat gun to make 4 corner pieces separate.

Z clips you only need chop saw. http://www.eagle-aluminum.com/Eagle-Z-Clip_ep_42.html

It is pretty low tech. Inside frame is two half's made out ACM with plywood for rigidity and industrial expanded foam as a filler. On top of than 2" xps foam (pink insulation), tread is routed from 1" foam to copy tires my costumer sells. Round profile was done with belt sander. Hard cote is...

All done in house. Tire is 98"x20". Made out of ACM, XPS foam, polyurea coated with cartridge gun.

Shop bot is pretty good and it's in your price range. How do you cut your channel letters?

I did a sign for a restaurant about 6 months ago. Sadly they closed a month ago. New owner called and asked for a quote on the new sign. He wanted to save some money by reusing the old sign. My response was I cannot reuse the back of the sign because of the support system I built into the sign...

I am trying to suggest way of mounting not a way of construction.

What I am talking is to a attach bigger surface acrylics or polycarbonate pads with silicone and then glue standoffs to them.

All depend how big is the letters. If they more than 12" tall I would make 1/8 thick acrylic pads with bigger surface area and glue them to the standoffs with weld on 4 and then silicone them to the letters.

http://www.graphicsone.com/go-f-24-uv-led-flatbed-inkjet-printer.html

How big is your letters? I would recommend to cut template from 1/8 hardboard with a jigsaw. And when use a hardboard template and hand router with bushing to cut hdu.

Expanded pvc would be my guess.

Pvc will take any good quality acrylic paint just scuff it with 220 grit sand paper and wipe it with alcohol. Here is example of two layers of pvc 0.75 and 0.5

http://www.p-led.com/Qwik_Stik.html

You can buy 2x5x.125 aluminum extrusion and cut it to the size. You need to buy two sticks and bend it on the brake. Than take it to local metal fabricator and they will powder coated for you.

It would be very interesting for me as Linux user for a 12+ years and sign maker for 4+. I would really appreciate if you share with us your experience.

Are you referring to water base urethane paint or acrylic latex paint.

My costumer wants 200 domed labels oval 0.5x0.75 . I don't like doing them in house.

Then I was working for other sign shop they paid me $16.50/hr. I am slow compare to other installers. Average wrap will take me about 10 hours from wash to taking a pictures for portfolio. Now I do work for myself but I still do installs for other sign companies for $2.50-3/sq.ft.

you are in luck http://www.ebay.com/itm/Promo-JET-Solvent-Flatbed-Inkjet-Printer-No-Reserved-/171187253944?pt=LH_DefaultDomain_0&hash=item27db8e32b8