UFB Fabrication
New Member
This is a lighted cabinet and should be made as such.. Use .080 back, cut to shape, weld on .063 returns, rout edges smooth, prime and paint. Lexan face is OK but I wouldn't use jewelite on this size piece. You need to fabricate aluminum retainers to the shape of the cabinet. Make it min 7" deep and use fluorescent lamps mounted close to the back. Sounds like a lot of work but is actually cheaper than a neon lit channel letter can and will last forever. Lamps not so long but they are easy to replace.
GG has it right. Trimcap is wrong for this application. The face is to large. Acrylic expands and contract 1 inch from freezing to 100 degrees for every 14 feet. I am not sure of the exact numbers for polycarbonate. Make sure the sign is UL Listed or CL in the case of Canada. If you dont already build or have the equipment this would not be a profitable experiment. Buy it from a decent wholesale shop. Not sure what is required as far as permit and electric licenses in your part of the world either so check on requirements first.