Production Method:

Precision-guided lasers, routers or jigsaws are used to cut the requested letter, logo or shapes from thin gauge sheets of stainless steel. For most letters, 22-gauge material provides the proper balance of strength and weights, while some larger letters require 20- gauge material to provide adequate strength. The letter returns are produced from narrow band material or cut to size based on the desired letter depth and bent to the contour of the laser-cut faces to produce a hollow-backed letter with 90 degree angle edges that have clean, crisp corners. The elements of this construction are hand-soldered using a lead-free silver solder. Tests on these welds indicate the ability to withstand temperatures below -40 degrees F and exceeding 350 degrees F. Uncoated or Titanium-coated stainless will have thin lines of exposed silver solder & stainless where there is a weld.  These tiny lines will be buffed smooth on polished pieces and stroked on satin pieces to maintain consistency in appearance. All fabricated products are either buffed, stoked or painted per specification. The standard polished material is a high-grade,   single directional polish. Virtually no grain is visible to the naked eye on these polished pieces.

Brackets (see the photos above - Click Photo to Enlarge) are soldered on the inside back of the letters to receive threaded studs. This involves a welded strap joining the letter's returns with a stud welded boss to accept mounting studs centered in the strap. This method produces a strong fabricated letter by giving strength to the already-formidable welded side returns. The workable space in the hollow of the fabricated piece dictate which combination of mounting hardware is used. As can be seen from the above photos. wide-stroked pieces will usually have straps with stud bosses soldered to them. Narrow-stoked pieces will have stud bosses soldered directly to the side or back of the piece. Intermediate-sized pieces may have a combination of the previous two methods.