This was a nice little challenge. We were hired to make a sign for the new Captain America film which will hang in the Disney Store in Times Square. The sign has to be lightweight, clean and look high end. The graphics supplied were really cool so we have a lot of work to do to match it.
I started with designing the “Captain America” letters. I thought it would look great to do it in two parts to match the logo – the outside letter will be cut out of 1″ 15lb Precision Board HDU and painted silver and the inside beveled plate will be cut out of 1/4″ PVC and we’ll print the blue face and highlights to it on our Oce’ 350XT Flatbed Printer. 
Stage 1 Complete!
Now we have to come up with the sign backer. Again it needs to be lightweight and look awesome – something Captain America… ish.
So we decided to make it out of 2″ Black Gator. At this thickness we’ll be able to drill down the center of the material and insert threaded rod to hang it. Here you can see Greg drilling the holes for the threaded rod. Once we have our rod in place we’ll wrap the sign with black brushed metal vinyl. Greg made up some nice low profile hangers to finish it off.
Here Rad and I are wrapping the panel with our Avery black brushed metal cast wrap material.
Stage 2 Complete! Great job Rad and Greg. 
Now we’ll finish up the other dimensional letters and get them over to Brian to paint – he’s going to do some nice airbrushing on our letters so I can’t wait to see them. In the meantime we have to complete the face of our sign. we are going to finish it off with a sheet of 1/16″ Frosted Acrylic with silver cast vinyl backer to give it a real sleek look. we are going to print some of the text directly to this panel then double sided adhesive mount it to our wrapped gator board.
All the elements are complete – it’s time to glue it all together. Mark, Rad and Eddie jump on the mounting and gluing. We are almost there.
