How to cut channel letter faces without CNC router?

[nolanola]

Hello Forum.
What tools and method do you use to cut channel letter faces when there are no files available? For example when faded faces need to be replaced.
The method I was told is to remove a channel letter can from the wall, put it on the table, attach to a sheet of acrylic with double sided tape, flip over and cut with a hand router with flush trim bit (with the bearing). That didn't always work well for use.
We tried Oscillating Tool with questionable results.

Thank you!

​

 

[signbrad]

Before CNC routers, all channel letter faces were cut by hand. The commonest tool was a sabre saw or jigsaw. I used hollow ground blades with 20 TPI for very smooth cuts with no cleanup. Also used were bandsaws, handheld routers or a Cutawl saw.

Avoid cheaper acrylics—they melt behind the blade—and don't push the blade too hard. The hollow ground blades get hot, especially if you are cutting 2 or 3 letters at a time (stacked). The blade snaps when it gets too hot.

I kept 2' x 6' x 4-inch thick slabs of foam for a cutting surface.

Cutawl


Brad in Kansas City

 

[Billct2]

We'd trace it onto the new acrylic cover sheet and cut with a jigsaw. Like Brad said, get some cheap thick insulation foam board to cut on, makes it easier.
We used to do these on a bandsaw, remember one place that had the deepest throat bandsaw I ever saw, they could do 6' letters.

 

[Scotchbrite]

Like others have mentioned, a variety of tools were used. Jigsaw, vertical bandsaw, and hand router is what we used the most.

 

[gnubler]

This was covered in depth in a thread I started last winter. Similar situation - replacing old faces with no artwork for the existing letters.

Mildew/grime inside lit channel letters

I got a call from a customer about "dirt" in a lit channel letter sign and if I could service it. Checked it out during daylight today and the signs looked fine, went back after dark and saw dark streaks running down the interior of the face of every letter, mostly pooling at the bottoms of the...

www.signs101.com

I ended up passing on the job. Six months later I still see those grimy letters up there, nobody wants to touch it.

 

[WhiskeyDreamer]

my mentor would have answered your question with "very carefully"

but yes, without a cnc, trace the shape onto acrylic and cut it out with a jigsaw.

 

[gnubler]

As was discussed in another thread, if the sign is old the trim cap might be brittle or cracked, and you'll have to deal with that when putting the new faces in.

 

[nolanola]

As was discussed in another thread, if the sign is old the trim cap might be brittle or cracked, and you'll have to deal with that when putting the new faces in.

We replace the trim as well.

 

[Johnny Best]

Back in late sixties and seventies it was a deep throated bandsaw that cut the acrylic like butter. Jigsaws work well if they were to big for the bandsaw. Cutawl is the fantastic tool but have not seen one for years and that is the one tool I should have never sold.

 

[JQUEST]

Cutawl is the fantastic tool but have not seen one for years and that is the one tool I should have never sold.

I almost bought one a couple of years ago. I should have...

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