Best stencil material

I always just draw the pattern directly on the substrate then paint with a brush. Thats the way the sign painters do it and it makes a superior product.

If he has it on computer already, he could just get his hands on a projector, project the image onto the sign substrate and trace the outlines.

Of course, instead of doing it this way, if he finds someone with CNC plasma he could have them cut the characters from sheet metal, add some weld studs, powder coat and then attach to the substrate and have something that should last a long time.

I did a 4' x 8' sign for a friends business a few years ago by plotting the sign on ordinary plotter paper and then cut it out with an Exacto knife. I painted the plywood the base color with exterior enamel and a roller. Once it was well sealed for weather, I put the stencil on the board and spray painted the signage with a rattle can. It took a few coats with the rattle can. When it was done, it looked great from 10' and held up for 5+ years in the New Mexico sun and mild winters.

The stencil only survived the one use, but would have been simple to reproduce.

One of the things I did that helped was to spray the back side of the stencil around the characters with artists mounting adhesive. It helped the stencil stay tight on the board until it was completely done, but came up cleanly with careful pulling.

Good Luck, Bob

"Karl Townsend" wrote in news:475c1216$0$40796$ snipped-for-privacy@auth.newsreader.octanews.com:

Were it me, I'd have it laser cut out of 22-28 gauge aluminum sheet. Use an easily removeable tack glue to hold it in place while working on it, then roll it up and store it for when the signs need refreshing again.

How about a piece of 1" 11-ply have a sign shop use your file to cut the letters out of rubber sheet. Stick the rubber on the ply and sand-blast it to 1/2" deep arounf the letters. Seal and paint the shit out of it or stain and urathane it. It will last forever...with fresh paint or urathane once in a while.

Carve it into a handy tree?

I would suggest either the cutting out of paper-3M-spraymount-rattle can approach (used it for smaller stuff in one colour and it works) or the commercial vehicle/sign shop vinyl approach.

Mark Rand RTFM