What is the best to bond PVC to Alum?

[Kottwitz-Graphics]

I just went to look at a sign that I built last year, (yet to be installed because the contractor wanted some electricians to install LED rope lighting).

As we are going over the job, I noticed that there was some delamination between the layers. So now I gotta pull it apart, and re laminate the parts back together...

The sign is a 3/4" PVC, drilled to accept studs and gemini mounting pads, bonded to a brush finished alum, slightly oversized, and then 1/4" PVC letters that were painted a custom "blue" were mounted on the face of the brushed alum. (so what you see is 1/4" PVC blue letters, with a brushed alum outline. The alum is bonded and attached with screws to the 3/4" which is hidden from view. It's only there for strength and stud mounting)...

I used West Systems epoxy to bond the letters, and now its falling apart...

So now to the heart of the question... What can I use to bond the 1/4" pvc letters to the alum? I wish I could just screw them on, but they required no visible fasteners... So what double sided tape will be best for this application...

Thanks in advance,
Mark

 

[J Hill Designs]

I use mactac IB2107 laminating sheets - they come 17"x22" or something - never failed me - I do a lot of PVC base with .040 brushed, router cut letters

 

[Christian @ 2CT Media]

We use GFP Permanent/Permanent Mounting Film. I believe its a 3mil thick film with super aggressive bond.

 

[Eric H]

Silicone and/or vhb tape. PVC moves alot the aluminum doesn't, some sort of flexible adhesive would work best.

 

[J Hill Designs]

unless the letters in question are huge, they wont move much at all

 

[artbot]

whatever it is, it has to stretch. thermal expansion and turning/torquing around is probably what broke the bond. VHB is a good option because it can stretch and is and active adhesive. i like to go with dual adhesives for some things too. one that is best for peel, one that is best for shear. and always abrade the surfaces as much as possible for high risk bonding.