On the sign I last posted I forgot to take pictures of the assembly process, but luckily there was a second identical sign. Since I designed the signs to slip into the framework of the lighthouse sign they needed four legs to protrude out of the back. The signs are routed in three layers with the center one inch thick layer having slots in to to accommodate the framework. With the sign face down and the second layer in place I put the pieces of steel into the slots and tacked them up. This made things real accurate. I then put in some temporary spacers and set the back of the sign on those. The short pieces of square tubing were then dropped through the 3/4″ thick sign back holes and welded into place. Once the frame was completely welded up I cleaned the layers up and put it back together one last time only with one part PB Bond 240 (Coastal Enterprises)- a one part urethane glue that is activated with a spritz of water. I then used screws and clamps to keep everything in place – FOREVER.
