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alliminumsignbox

alliminumsignbox

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Published by: darl1 on Feb 26, 2011
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PRACTICAL SIGN AND DIGITAL GRAPHICS
ISSUE 46
MARCH/APRIL 2010
Visit www.signafrica.com for the latest news
69
FEATURE
PRE-PLANNING
You need to ask the followingquestions to determine thelightbox you want to manufacture.Determine the size of thelightbox you would bemanufacturing. (Remember,when using the Mae WestCorner connector to deduct66mm in total (33mm per side) from your Mae Westextrusion, e.g. if the lightbox is1000mm
2
, cut your extrusionsto 944mm in length.)Establish if you want to makea box with either a rigid signface (Palglas opal acrylic andh-prole) or a exible sign face(Prol PVC Tensioning Systemand 1000D Backlit PVC).Will the box be singleor double-sided?Will the box be displayedindoor or outdoor, as thiswill determine the width/ strength of the extrusions?Conrm positioning of thelightbox e.g. suspended fromceiling to the top extrusion(ceiling mount), side supported(between posts/pillars) or basemounted. This is important inorder to determine from whichside the Palglas acrylic is to beremoved e.g. slide from sides,out the top or from the bottom. One must always keep in mindthat the Palglas Acrylic andpre-wired light ttings are onlyavailable in certain standard sizesand to work your box aroundthese measurements accordingly.In this exercise we will be usingthe Mae West 150mm widealuminium extrusions and thealuminium corners to t thisprole. (The Mae West Aluminiumextrusion can also be mitredat a 45° angle and then joinedwith a 50 x 50 Angle Iron.)The actual size of the frontface of your lightbox will varydepending on the aluminiumh-prole that has been usedwith the relevant extrusion.
Various alternatives to the MaeWest extrusion are availablefrom your Falcon ofce.
WHAT Do yoUNEED?
150mm Mae WestAluminium ExtrusionBaby h or Big h extrusionEither 050 Palglas Acrylic in 3or 5mm or Hex-Flex 1000D x 1000D Backlit White/White  PVC4 aluminium corners to tthe Mae West ExtrusionPre-wired light assembliesto t lightbox sizeElectrical wire to connectlight assembliesFlat head self tappingscrews and rivetsWhite Chromadek for backing, if single-sidedPower supply cable to connectlightbox to external power supply. (Ensure you use thecorrect type and size of wiringe.g.; if outside then select UVprotected aluminium insulatedwire – always check withyour accredited electrician).Plastic Grommet or Compression Gland (to insulatewiring from the aluminiumextrusion which is a legaland essential requirementin accordance with Wiringcode SANS 10142).25 x 25mm Angle Ironto mount light ttings if lightbox is double-sided.4 ttings and uorescent tubes.
TooLS REqUIRED:
Electric/Portable DrillMetal Drill bitsTape MeasureScrewdriver bitsMitre saw (when cutting 45°angles, manual or electric)Rivet GunSide Cutter and pliersNT KnifeHammer and piece of woodor White Plastic MalletGarden Scissors (ProlPVC Tensioning)
ASSEMbLING THELIGHTbox:
1. After the Mae WestAluminium has been cutto size, insert your MaeWest corner connectors tothe Mae West extrusions.Use a piece of wood toprotect the aluminiumfrom being damaged/ scratched when using ahammer or white rubber mallet in the assembly.2. Secure the pre-cutChromadek to the back of the box with the white sidefacing into the lightbox (remember to remove theclear protective layer fromthe Chromadek Sheet).3. Attach the pre-wired lightttings to the Chromadekwith pop rivets (it isrecommended that you placethe light ttings
±
200mmapart on a single-sided box and
±
80 - 100mm apart ina double-sided lightbox.)4. Now connect one uorescenttube to the other inparallel. The rst pre-wired tting would be thetting closest to wherethe power cable would beconnected. Then attachcorresponding colouredwires to each other. Nowconnect correspondingcolour wires to a centralpoint and connect thewire bundle to a cableconnector (also knownas “chocolate block”).
 
STEP by STEP
PSDG MarApr 201003 2.indd   69 3/1/10   12:10:16 PM
 
FEATURE
PRACTICAL SIGN AND DIGITAL GRAPHICS
ISSUE 46
MARCH/APRIL 2010
70
Visit www.signafrica.com for the latest news
5. Drill a hole into the sideof the lightbox where youwould like the power supplycable to run through. Fit theplastic insulating grommetonto the external cable andthen insert into the drilledhole. Connect the externalcable to your chocolateblock as per correspondingcolours. (As illustrated inthis picture Red – Live, Gold– Earth, Black – Neutral)
Please note: Only an AccreditedElectrician is allowed to connect a lightbox to a power supply.We strongly recommend your Accredited Electrician inspectsall wiring of your lightbox as a precautionary measure.Always obtain a wiring certicate after installation.
oPTIoN 1 :LIGHTbox WITHPALGLAS RIGIDoPAL ACRyLICFACE
A Attach either the Baby-h (If you need a 3mm PalglasAcrylic Face) or Big-h (If youneed a 5mm Palglas AcrylicFace) extrusion to the frontof the lightbox. Attach 3sides of the h-channel aspermanent xtures andthe fourth section withself tapping screws to beable to remove acrylic for maintenance to the lighttting on a later stage.B Remove the protectivelayers from the Palglasacrylic sheets, andapply the vinyl onto thePalglas Acrylic, beforeinserting into the Baby-hchannels. Attach lasth-section to lightbox.C Power up your illuminatedlightbox, and marvelat your creation !
oPTIoN 2 :LIGHTbox WITHHEx-FLEx PVCbACkLIT FACE(FLExIbLESUbSTRATE)
Important Note:Depending onthe length of your lightbox and in order to avoid any concavingoccurring along the length or widthof a large lightbox, additionalinner cross section supports may be required to add strength and accommodate the tensioning of the exible substrate.)Do not underestimate the tensioningstrength of 1000D Hex-Flex PVC.
A You will need to purchaseProl lengths, whichcomprise three components:Prol TSW – bottom channel, 
in the shape of a C.Prol Gripp – middle 
white plastic extrusionto grip the PVC.Prol Key – top aluminium 
section, to add nal doublelocking tension with anaesthetic aluminium nish.2.2 Position the lengths(Sandwich of ProlTSW+Gripp+Key) 90
°
eachother, along the four corners of the box. Wherethe lengths meet, cut eachcorner at a 45
°
mitre. After cutting the 45
°
angles onthe corner of each length,check again that each mitremeets each other perfectly –then you have a perfect 45
°
 mitre cut on each corner. Itis crucial now to mark eachside with a number, so thatwhen you are installing alltogether, each side matcheseach 45
°
mitre corner 100%accurately, as planned.B First attach the Prol TSWchannel to your box usingat head self tappingscrews.  Important to notethat the self tapping screwsmust be narrow enough tot into the channel withoutcausing the channel to bewidened or disgured inany way as this will reducethe effectiveness of thewhite plastic Prol Gripp.C Position your printed BacklitPVC onto your lightbox.Using a pair of gardenscissors or sheers, cut your plastic Prol Gripp 20mmshorter on each side thanthe length of your ProlTSW. Ensure your PVC printhas at least a 100mm bleedaround the printed area toensure easy tensioning, aswell as preventing the outer border of the graphic imagefrom being cut out or skew.D Start from the top middlesection of the box andknock in the Prol Gripp ata 45° angle with the smoothside facing inwards towardsthe lightbox, with thetoothed ribbed side facingoutwards (i.e. towards you).
PSDG MarApr 201003 2.indd   70 3/1/10   12:10:23 PM

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