Attaching large letters to stucco

[brian]

I've been asked to do a sign from either alupanel or poly coated foam.
The building is stucco over ship lap. The sign overall will be 28' long with individual letters.I'm thinking of using stainless metal bolts behind the letters using epoxy or polyurethane glue set in drilled holes.
Is this the best method or does anyone have any better ideas.

Also should I make the letter removable in case of any damage in the future.
I know this would be harder with the foam as the bolts would generally be set into the back of each letter.

I was also going to use a plywood mounting jig.Since the sign is 40' in the air I though it would make it much easier to set the plywood against the wall predrill all the mounting holes remove the jig then mount the individual letters.

Any thoughts or seasoned wisdom would be welcomed.

Brian

[CNYDWW]

How about stainless keyhole hangers. Minimum 2 per letter and a little trick, RTV silicone in the keyholes just before you hang. It will keep them mounted firm but if they have to be removed the silicone will give way. I would suggest a little practice.

Regards
Randy

[t_vandemark]

Check out Melissa Jones with Nice Carvings. look on their website in the letter insallation section. I believe this might be what your looking for, there is a great video on how they work. :)

[dakers]

http://www.htm-system.com/component/option,com_virtuemart/Itemid,17/lang,us/vmcchk,1/

this is what nice carvings uses on some things.
the main thing is getting a good bite on the letters.
you can use any system if you can do that.
the smaller ones are not recommended for letters over 28'' tall and the letters should be light weight.
they have an "expander version" that does not have letter height or weight specs but you can email them or call them to see if this product would work for your application.
i have never used them but they are very interesting.

i would use stud mounts, possibly using the Gemini mounts with the largest pad possible for the stroke width glued to the back of letter with the appropriate glue and the stud going into the letter with glue in the hole the stud goes into if it is hdu letters. we have never had a failure with that method and they can be removable, it all depends on the weight of your letters as to how many you use.

the key hole method would work as well as modified cleat method but do not know enough about what your letters are to make a 100% goof proof recommendation.

the plywood template would work if you want to use something that heavy. i usually use paper but reinforce the edges with tape so it does not tear in the wind. can use cardboard, coroplas or tyvek if you want something more durable. i would get a two man bucket or lift (with fall protection) on the proper ground surface to do this as it makes putting template on easier and faster.

around here i would be reluctant to use the quick snap if snow will build up behind the letter.


Quick Snap Letter System

HTM-System is proud to bring you a modern option for mounting your cut letters!
HTM-System Quick Snap fastening system is designed to provide you with additional options to traditional mounting of cut lettering. We have a solution for small delicate lettering as well as larger bold letters. Simply screw the head to the mounting surface and adhere the body to the back of your letters.
The Quick Snap installation method allows you to install your lettering in one trip. There is no need to return to the job site to remove tape or other securing items sometimes needed when you have to confirm that the adhesive has been cured. You simply install and can be confident that your job not only looks good but will not require additional man hours and travel time.
The Quick Snap fasteners are available in a variety of colors and styles allowing you to find the right product for most any letter mounting project.
HTM-System
2401A Corporate Blvd
Brooksville, Florida 34604
Phone: 352-796-4272
E-Mail: sales@htm-system.com
Website URL: www.htm-system.com (http://www.htm-system.com/)

[brian]

Thanks for the info
Here's an outline of the sign
The largest letter will be 35" tall x 40"wide.the total sign size is 24' x 14'
Are these letters to large for SM foam covered with a hardner or would alupanel be a better product.
This sign is quite high up.The closest anyone can get to it is around 70'
At that distance is the 2" depth that foam gives the sign important or is it lost.
Alupanel would be a cheaper material and easier to construct coming in 4 x 8 sheets.
The sign will be individual white letters mounted to the wall
Again any wisdom is appreciated
Sorry for the small picture,the file size limit wouldn't allow anything bigger

Thanks Brian

[dakers]

we have used signfoam for letters that size but i realize it cost more and budgets come into play.
i really appreciate you thinking out of the box on using foam and hardcoat.
reminds me of the work here.

http://imaginationcorporation.com/
i think Dan could give you a better answer than i ever could as well as others here.

i always try to think of how to do things so they can last a decade or longer. i am not saying the foam insulation with hardcoat will not last that long. it probably would have no problems if painted and maintained same as any other material.

so add these thoughts to the mix for the alupanel and the foam but you have to decide.
i am assuming the wood behind the stucco is in great shape also.
with stud mount i would use alot of glue in the hole i drill in the building.
the problem with that is usually when they have to repair the wall when the letters are removed. but if you use long stainless deck screws through the face of the letter it does not make a large hole and can be repaired alot easier.

i do not have any experience with 2'' foam insulation letters that size with hardcoat as far as warping and rear fastener methods, etc. since they go so high in air i would opt for fastening with stainless screws through the face. painted same color as letters. probably 4 screws per letter. at that distance they would hardly be noticeable. or i would glue 1'' x the largest size square or circle of 15lb signfoam squares or circles to the back of the lighter weight foam letters before it was hard coated then glue large gemini pads with long studs going thru the signfoam into and into the letter then hardcoat over them. or some variation of that idea. I would get studs that reach beyond the wood behind the stucco.

if you can get behind the stucco wall many installers attach letters that way using nuts that fasten to the studs but it is more time consuming

on the alupanel letters i would probably sand the paint off the back in spots where i would then glue large as possible squares or circles made from of 1/4'' mill finish aluminum to the aluminum skin using two component lords adhesive to glue aluminum to aluminum. the 1/4'' aluminum would be tapped to accept studs. Would use thickest alupanel 6mil .Some on the forum are using the 61-081 (1/4 CED, 3/8 CEL, straight edge O-flute) at 14 000 RPM and 2"/sec. with 1/8 stepdown (through cut) ramping in the cut
This two component Lords Adhesive for aluminum is the most amazing adhesive. it is used to build aluminum sign cabinets in lieu of welding.

there are alot of different materials and choices these days. i wish i knew more about foam with hardcoat. i did get some sample hardcoat and it looked really good.
i know there is are different densities: 1LB Density: Construction use, insulation, arts and crafts and cake interiors
2LB Density: Hot tub covers, construction use, insulation and arts and crafts
3LB Density: Hot tub covers, construction use, insulation, and arts and crafts