DIY Project – Bring Your Stapler

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Spoke to a customer a couple of weeks ago.  They wanted to build their own sign.  So, we gave them the advice they needed.  We sold them the letter track and the letters.  And, we curiously waited to see if we would get a report of how it worked out.

A few days after we sent them their “stuff” we got these pictures.  The were very “happy” and “pleased” with the results.  In our busyness, we neglected to get the pictures up right away.  A couple days after the pictures arrived, we received a call.  The caulk they used to adhere the sign track to the board was pulling loose.  Not all of the tracks, but enough that they were looking for another solution.

While I thought I had mentioned our use of a staple gun during the early part of the process, the issue now was getting them happy now.  I emailed them the stapler information I have written down: (I just wrote the info down provided by my sign guy)

Craftsmen 10 AMP (Sears #[I think} 968492 Easy Fire Staple & Nail Gun

Staples:  Narrow Crown Heavy Duty (Not Arrow – problems with the teeth)

  • 3/8″ Standard
  • 5/16″ Hardwood

Since the sign has gone up, they have ordered more track and more letters for another sign.  Either they mastered the caulking technique OR they bought a stapler like we suggested.


Specifications On Our Fluorescent Vinyl

The vinyl we use outlast any other vinyls we have tried.  It does cost more, but we believe its life span makes its cost well worth it.

We do stock 5 of the 6 standard colors:  (We do not stock the blue.  If requested, for a large enough order, we could also stock.  The fluorescent blue is really to dark to show up well on black, but it would work on white coroplast.)

  • Yellow
  • Pink (Fuchsia)
  • Red
  • Orange
  • Green




The Neons are a high performance cast vinyl fluorescent film series providing dynamic graphic accents for indoor and outdoor uses. It can be used for marine applications, automotive aftermarket windshield graphics and accent strips, retail window signage, trade show exhibits, and point-of-purchase displays.


  • Automotive
  • Marine
  • Point-of-purchase displays


  • Unique colorant system for enhanced visual impact and exceptional opacity
  • 6 Standard colors


  • Color and Finish 3.8 mil High Gloss cast vinyl
  • Adhesive Permanent Acrylic (528A Adhesive)
  • Liner 78# Kraft


  • Average Adhesion Values 20 min. 24 hr.
  • (PSTC-1, 180° peel @ 10”/min., 73°F, on Stainless Steel) 50 oz. 72 oz.
  • Minimum Application Temperature 40°F
  • Service Temperature Range (peak values) -50°F to +225°F
  • Elongation 80%
  • Dimensional Stability (48 hrs. @ 150°F) .025”
  • Shelf Life (@ 73°F, 50% RH) 1 year
  • Outdoor Life 2 years for vertical exposure in a temperate climate. Exposures less than vertical or in hot climates or near sources of heat such as engines will reduce durability


  • Distilled water (24 hrs) No effect
  • SAE 20 motor oil (1hr) No effect
  • Gasoline (10 min.) No effect
  • 10% HCL (10 min.) No effect
  • 10% NH4OH (10 min.) No effect
  • The above information is based on research believed to be reliable, but does not constitute a warranty.
  • All material should be tested by the purchaser to determine suitability of the product for their purposes.


Plastic Letter Sizes



Over the years, a variety of sizes of black sign letters have been made.  The above image packs in LOTS of information.

  1. There are basically “two” sizes of letters.  There are the 8 inch (7 7/8″ letters and the 16″ letters which are approximately double the size.  The 16″ letters take up twice the height of the 8″ letters while “skipping” the track.) and 10 inch.  (Same as the 8″ letters, but the letters are 10″ and 20.5″.)
  2. When the letter sets are created, there are 3 sizes of coroplast that are needed.
    • The “R” size is used by almost ALL of the letters and most numbers and most symbols.
    • The “I” is used for one letter/number and a couple of symbols.
    • The “M” is used for only the M.  It is our widest letter.
  3. There is also a 4″ and a 5″ letter set on the list.  Those were used for our sidewalk signs and banners.  Unless your our TOTALLY duplicating our business, it probably won’t be of much need to you.
  4. On the image with the letters, the contrast is seen between the size of the letter panel and the actual letter.  (The letter panel is the piece of coroplast the letter is attached to.  The letter is the vinyl letter attached to the coroplast.)
    • On the 20 inch letter [actually 20.5 inches tall], the letter is 18 inches tall.
    • On the 16″ letter, the letter is 14 inches tall.
    • On the 10″ letter, the letter is 9 inches tall.
    • On the 8″ letter [actually 7 7/8 inches tall], the letter is 7 inches tall.

There is more of this detailed stuff to post, but hopefully this gets us a common set of terminology.