What type of PVC to use for pocket letters?

[blackhawk]

I am making a sign and I want to use the pocketed letters technique. I am tired of painting letters on the sign. I have never used PVC for anything but drain pipes before.

What is the correct type of PVC to use for cutting letters? I see all the brand names such as Komatex and Sintra. I get most of my supplies from Harbor Sales and their descriptions call these PVC sheets "rigid foam". That description makes me think that this material will have air pockets/voids once it is cut. If you have recommendations, could you give me exact names and or part numbers of PVC sheet.

The other problem is that I only need a little more that 1 square foot of material, so I don't really want to buy an 4x8 sheet. Lowe's sells PVC boards in 3/4" thicknesses and different widths. Would this type of PVC work?

[jerry_stanek]

Harbor sales sells Komatex Sintra and other PVC any one of those is what you want.

[kurt_rose]

Hi Brad. I use Azek trim board or any of the exterior pvc's left over from construction jobs. Works great. Latex paint sticks to it like glue. I have a friend that's a siding contractor and he keeps me full of stock just with his drops.

[kurt_rose]

Joe Crumley should be chiming in on this and I'm sure he'll give you the real scoop. P.S. The 10 min. edit rule stinks!!!

[bleeth]

For exterior use stick to the white and paint it with acrylic paint. The colors, particularly dark like black, don't do to well outdoors. Nice thing about pocketing is the letters are easy to paint prior to mounting. Cut edges will cover just fine-the material is pretty dense.
Don't know for sure but I though Harbor sales will sell less than full sheets.

[jerry_stanek]

I just got another job last night to cut PVC letters. Whole sheet nested letters are about 12 inches high Cut out of 25 MM PVC

[blackhawk]

Dave - Harbor will cut it to size for you, but they still make you buy the entire sheet.

I found a scrap of PVC trim that I used on my house a few years ago. I am going to try cutting that and see how it does. I can buy a length of that at Lowe's for less than $10.

This sign is for indoors. I thought about just using some HDU scraps that I have for the letters. My HDU is 1.5" thick though, I may be able to cut it down on the bandsaw using a resaw blade. I need a 3/8" or 10mm thickness for my letters.

[pappybaynes]

I use Kleer Lumber - I buy it 5/4" x12" x 18' - been doing historical building markers...works great