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Biggest Tray sign size with Dibond
Hi what is the biggest tray sign you would make from 0.3 composite panels ? we have just done one 1.45m x 6m, some trade suppliers say at that size it should be made from aluminium.
Thanks
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11 Replies
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What’s going on the face. It could definitely sag in the middle with the weight of acrylic inlays
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Its just got vinyl applied to it. with 60mm returns.
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If you don’t mind me asking, why the tray!
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? Not !
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I would imagine the limiting factor is the strength of the folded returns. A sign pan made from aluminium is going to be a lot stronger whereas composite is relying on a single thin face of aluminium to handle the weight and wind load of a large pan. Perhaps the folds could be strengthened by applying a bead of 2 pack glue in the groove once the panel has been folded? And any tendency for the front face to sag can be countered by fitting strips of folded dibond behind the face to aid rigidity?
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My hubby did one 4 x 8×4 sheets portrait. So that’s gotta be close to 5m
He made supports for the middle out of osb so the middles/edges didn’t sag and gave additional support
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Done a lot of really long trays. In excess of 10m x 800 to 1140mm. 40mm returns. CLS frames.
And a few ‘double trays’.
None of that cheap hoarding board, all 0.3mm skins with full depth framing. Quite happy to do 3m high x whatever if you can get the joins well supported and locked in.
Work well but must be really accurate.
Few I’ve done.
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Nice work. Do you have your own cnc David?
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quote Kevin Mahoney:Nice work. Do you have your own cnc David?
No – I use a big plunge router with a flat 6mm bit. Gives a nice radius when folded (and allows for overbending to get it to relax at 90 degrees). Also much, much more forgiving as you don’t get a hard crease that can overstress the bend.
Tried rounded, tried 120 degree – not a fan of either.
40mm guide, sheet just hanging off the bench…set depth to about 0.25 to 0.5mm before the back alloy…happy days.
I never go for the ‘fancy’ corners either. Straight out & check / cut out the square that’s left leaving 2/3 of the groove in place. Fold in…perfect.
Typically set it to 40mm returns and use 38mm CLS timber as a back frame – plenty of support.
I’m making a small 2400x1100mm tray later on today / tomorrow. Will post up a few photos / video if I remember.
Wee drawing of it…
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We use our Festool milling saw & get half decent cuts, plus the vacuum attachment means zero mess. I’m not big fan of the clever corners either so just cut 90 degree corners & rivet in a 50mm piece of aluminium angle. Not as neat as glued joints but we can forget about the corners opening up which we’ve had in the past with bought in trays. I still want a cnc though, outsourcing is pulling all the meat out of the job. -
Did these ones today
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