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Honestly, given the state of things, I would use SIGN FOAM. You are routing the signs, presumably with a CNC router. Sign Foam routes like butter. You can get any density, up to 90 ponds per cubic foot but the 15 lb. or 20 lb. foam is sufficient for your purposes. You route it, spray it with a white FOAM FRIENDLY primer base, and then paint the letters by hand with ONE SHOT sign paint.
Sign Foam is a closed cell foam that is impervious to weather. It doesn't rot, or shrink, or crack. Termites don't touch it. It handles wind and rain like a champ. It is EASY to make very decorative signs because a CNC router carves it like a stick of butter! No knots. no grains. No issues!
I made this car lot sign five years ago, and it still looks brand new! The storage sign was fun, but the company changed its name shortly after ordering the sign.
Joe
Sign Foam is a closed cell foam that is impervious to weather. It doesn't rot, or shrink, or crack. Termites don't touch it. It handles wind and rain like a champ. It is EASY to make very decorative signs because a CNC router carves it like a stick of butter! No knots. no grains. No issues!
I made this car lot sign five years ago, and it still looks brand new! The storage sign was fun, but the company changed its name shortly after ordering the sign.
Joe