Halo Lit Custom Channel Letter Sign

Our friends at Crestron Electronics hired us to create a front desk lobby sign for their headquarters.  We’ll be creating custom channel letters with high gloss black finish mounted to a satin metal box and lit with LEDs.  The challenge with this sign was that the box was about 110″ long and our cutting bed was only 96″. So with some creative maneuvering we were able to make the cuts.

Here we are cutting the letters for our sign out 1.5″ 30lb Precision Board.  These will be real heavy duty letters and the 30lb density foam will allow us to get a nice smooth finish. You can see the drill holes for the screw posts which we will use to mount the letters once complete.  We have also hogged out a channel to allow for our LEDs.

cnclettersHere is cut one for the back side of our box. As you can see we cut only the first part – we then had to move the sheet of dibond and reregister it to the MultiCam table to allow for the second cut.cuttingbox2

Complete! and ready to mount the letters.


Brian has all the letters back from the paint shop and ready to go.


It’s time to install the LEDs, wire each letter and logo element then and then wire up the box.

wiring 2

Here Mark is measuring the LED output and calculating the final letter height.

markThe letters are going on nice and smooth but there is still a lot of wiring to go.


All done and ready to be installed.