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Big Lighted Letters and numbers

3K views 29 replies 7 participants last post by  jw2170  
#1 ·
Quick summary - My daughter is starting a rental business renting tables and chairs and big lighted letters for events. I am doing the woodworking part building each letter or number. Her husband is an electrician and is doing the painting and installing the light fixtures.
Plans were purchased from a seller on ETSY. Several file formats are included with the plans so, someone with limited tools can also build them. I have a CNC so I am using it to cut out the backs which form the shape for each letter or number. We also have several symbols like the hashtag, ampersand and the question mark. Pretty much everything you would need for an event like weddings, graduations, birthdays, stuff like that.
Each letter is cut out, then the sides are attached. They are 4 inches wide. We are using 3/4 inch Baltic birch, which is attached to the 1/2 inch plywood backs. Lawdy mercy, some of those angles really were difficult for me to figure out, but I am getting better. The "H" I put together today went really fast. I wish they were all like that.
Each letter is 4 feet tall. Well, actually 47 inches. I use a flush trim bit to clean up the holes for the light fixtures, then an 1/8 th inch round-over bit to ease the edges. Looks much better when finished.
They are turning out nice. The light fixtures are better quality than what is suggested by the plans. I had to alter the dxf files to make larger openings. The lights that were purchased are "smart" which allows the user to control them via a phone ap so the colors can be changed or even work with music. I haven't seen that yet. Maybe this weekend.
So far, we have built 1, 5, and a 3 for upcoming birthdays. And I am finishing building the last of the letters for OH BABY. Then there are several more birthdays so a 6 and a 7 are needed for 16 and 17th birthdays. This weekend the 15's will be set up at our granddaughters 15th birthday. I am hoping we get a booking or three from that. Bella is on the Summer Creek High School Dance Team so maybe someone else will need some letters. Sadly, I think we have missed the "GRAD" scene. Just didn't get started in time.

Sorry about the rambling. Here are a few pictures of what has been going on.
 

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#13 ·
Hi Mike, love the project. Fun to figure out and make, lots of angled cuts to join. A high school chum who taught theater set and design at a Los Angles university, did a set for the musical Company. He had four huge panels that opened like a book and the bottom panels moved in and out as backgrounds for different scenes. And he had platforms on tracks that moved in and out for different scenes. But the most amazing thing was that at the end, the Book closed and up and down he had running lighted letters spelling COMPANY that ran vertically from floor to top of the proscenium. Spectacular! After that, he got commissioned to do sets for the Mark Taper Forum in L.A.
 
#14 ·
And the beat goes on! As of today, I have built 31 total letters or numbers. The last 6 are 2 foot tall and spell "MR&MRS". They look great when sitting on top of the 4 foot letters. I also made several pieces that act as feet and will bolt to brackets that can be attached to the back of the 4 foot letters. Our daughter has bookings through the end of the year and I have several more letters to build including a second A, N, and a D. and a 1 for "DAVID 11". And as they say in Amazing land "Out for delivery"! :)
 

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#19 ·
I got called upon to help deliver these numbers to an event. Two events going at the same time in different parts of town. Always glad to help out. With iffy weather headed our way, we loaded the truck with tables, chairs and these two numbers. We made it just in time. It is pouring down right now.
 

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#21 ·
The "electricians" checked out the lights with several lit up and almost no registration on the amp meter. Cool also. Color can be set for whatever color is desired. Daughter has a sack full of spare remotes! I think 4 remotes come with each set of lights. :)
In this picture, they were testing the new numbers that had just been completed. Two events on the same day. I ended up helping deliver and set up - one for "50" and one for "65".
 

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#24 ·
The beat goes on. Our daughter's daughter is a cheerleader at LaPorte High school here in Texas. So they wanted a Marquee Letter in their rental inventory that resembles the school logo. Here it is. I designed it and my wife helped me with light socket placement because there were way too many lights when both letters are combined. It is ready for paint and electrical. My job is complete.
I am also working on a 2 foot letter combo for an upcoming booking the end of September. It "LOS" to go on top of "DUENTES". Looking forward to see those lit up! Oh, yeah, I also designed the LOS so it would be one piece when the CNC cut it out. It's looking good.
 

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#27 ·
This big rascal is ready for the paint crew to take over. :). I was short on 3/4 plywood, so I took a piece of 1/2 inch and some 1/4 inch Baltic birch and glued 'em together to make a base for the "W". Then I cut it out on the CNC. Note: I didn't use any tabs to hold the piece in place after it is cut out. After some careful measuring, I set up a toolpath to mark where 2 screws could be drilled and driven through and into the mdf spoilboard. The holes are under the bottom of the letter so not visible to the public, and they are filled in from the bottom. :) And they worked great. No movement after the cutout was complete.
Onward through the fog! :)
 

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#28 ·
Today is the day! LOS DUENES wedding. My son in law posted some pics last night about 2am. He had just finished wiring the LOS and they were running a test on the lights. Here is one of them as set up in their garage. I build, they paint and install the lights. More to come later.
 

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#29 ·
Pics from the wedding are being posted. Looks like it was a beautiful wedding. It was son in law's cousin so they were there for the gala. Makes me happy to see my work in action. They used the treat wall for a display.
 

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