Augusta Sign Company

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Restoring the Billboard for Silver Lake Mill, Dayton, VA

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FRESH LOOK NEEDED

I remember meeting with Cheryl Lyon in my shop sometime early in the spring of 2020 after she sought out my company from a Facebook referral. She laid out across my shop table drawings and photographs of an existing billboard sign in Dayton that had deteriorated and wanted to hire me to upgrade it, sharing her artistic shematics for a new look.

Laying out the ACM panels for the billboard veneers on the shop tables.

The original mill on Silver Lake was built in 1822. It burned in 1856, was rebuilt, and was burned again during the Civil War in 1864. It was last operated as a mill by Rockingham Milling Co., which ceased operations around 1990 after constructing a new facility near Harrisonburg.

The top ACM panel cut to shape on shop table.

HISTORY RESTORED

Lyon, a member of the board of the Harrisonburg-Rockingham Historical Society, heard the mill was up for sale and thought it would be an awesome building for her growing specialty glass ornament business and purchased it around 1999. Soon afterwards she had an advertising sign erected by another firm to direct local customers to her business, which was a distance off the main road, Route 42. In order to erect an off-premise sign she had to coordinate construction of the sign with the Virginia Department of Transportation (VDOT) as well as the Town of Dayton and Rockingham County.

The primed aluminum ball finials waiting for the 23K gold.

After years of wear, the original sign lost its luster, hence her trip to my shop for fresh ideas. When Cheryl first approached me I was just finishing a custom church sign in Bridgewater and getting ready to start a huge job for the Blue Ridge Tunnel on Afton Mountain. I suggested she get in touch with me in June.

Inspecting the 3M digital print on the shop floor prior to application to ACM.
Loading up the trailer on installation day!

JOINT PROJECT

When June rolled in, Cheryl and I were able to complete the sign design work and applicable permitting via emails. I used help from Lisa Brady, a free-lance artist and graphic designer in Bath County, to provide several design concepts. Cheryl took care of the permit research. I always like it when customers secure their own sign permits. Especially in this case where so many agencies are involved in the permitting process. I was able to help with the cost worksheet needed by VDOT and also coordinated inspections with Rockingham County, but Cheryl did all the heavy legwork.

Doug Sheffer helping me with the installation; shown trimming one of the posts to fit grade.

Finally, in October, Cheryl was ready to pull the trigger on making a sign purchase. Once I received her deposit, I quickly ordered materials and began to fabricate the new sign. We took advantage of great weather, disassembled the old sign, and dug the 24 inch diameter by 4-foot deep holes for the new posts. We covered the holes with plywood covers and returned the next day to set the posts while finishing the sign in the shop.

Plumbing the posts and getting ready to install the new billboard sign panels.

TALKING SHOP

We laminated new 3mm thick Aluminum Composite Material (ACM) panels to the existing boards. Then we applied digitally printed 3M vinyl graphics to the ACM on one side and reinforced the joint between boards across the back. We fastened refurbished steel angles to the new 4 X6 X 15-feet long treated posts, and loaded up the trailer.

Doug attaching the 23K gold leaf finials.

Upon reaching the jobsite on the third trip, we hoisted the large 7-feet high X 7-feet wide sign up and between the posts, and fastened them securely. To finish it off, we attached the two 23K gold leaf ball finials to the top of each post and hung a separate directional arrow sign from the bottom of the main billboard.

The sign now up, but braced until the concrete cures. We used about a ton of gravel and concrete to pour the two footers. I think this sign will be around for a while!

On the fourth trip after a week’s time to let the concrete footers cure, we dismantled the bracing and touched up the posts.

NOT A RUN OF THE MILL PROJECT

The finished product!

All in all it was a very fun and interesting project and awesome weather to work in. I truly appreciated the chance to play a part in directing the public to the historic mill! It is reminiscent of the Savage Mill in Savage, Maryland, located about 5 miles north from where I grew up. That was also an old mill turned into a glass ball ornament factory before later becoming an artisan center. The reason I am familiar with it is because my Grandpa Hackley used to work in the original cotton mill before it too became an ornament business. He made Christmas balls there up until his death at age 79. Grandpa died instantly from a heart attack at the Savage Mill in 1964!

I hope I will go that way…while doing something I enjoy most…making signs!

Mark Hackley owns Augusta Sign Company, Staunton, VA

6 Reasons Why Metal Posts Reduce Sign Maintenance

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USED TO BE A WOOD GUY

Metal posts reduce sign maintenance!

I used to always make signs with treated wood posts, and they make great posts, that’s for sure. But here are six good reasons to consider an upgrade to painted aluminum posts for your next exterior sign project.

 

REASONS I CHANGED TO METAL

First, they just look good. Treated wood posts are never perfectly square on the corners. There’s always an imperfection somewhere. It may be a knot, or it may be a place that’s splintered, or sometimes a big nick in the wood, (no not Santa!) Painted aluminum signs on the other hand are always perfectly square, all sides always perfectly smooth. And they’re easy to clean without worrying about getting splinters!

Second, the bottoms don’t get eaten up by weed-eaters. I can’t tell you how often I see wood posts that were once 4X4’s or 6X6’s reduced in size at the bottoms by lawn equipment. It detracts from their visual appearance, and eventually the posts may fail at the base because of the weakened areas. Metal posts don’t seem to be affected much (if at all)  from weed-whackers.

Third, metal sign posts never warp or twist. Planting wood posts in the soil is kind of like playing Russian Roulette. Every now and then a post goes wild. I’m working on replacing a sign panel in a sign right now originally constructed of a wood post and beam system; and one of the 6X6 posts has twisted about 30 degrees. The posts are at least 15′ out of the ground, so instead of replacing the post, I’m just designing the new panel accordingly. But it’s just not the greatest thing to look at. A metal post will never warp as far as I’ve ever seen.

 

Fourth, you really are never supposed to paint a wood post, especially pressure-treated yellow pine. Besides leaving it natural, you can stain a wood post, but you should never expect paint to last very long. I do it all the time though and tell my customers to expect bi-annual maintenance. Metal posts are painted with acrylic enamels which are the same product cars and trucks are painted with. These types of paints are meant for endurance! You shouldn’t have to worry about repainting for 10 years or more, and you can wash and wax periodically to extend the lifetime even longer.

 

Fifth, with metal posts, you can easily incorporate strong cross beams into the sign design to hang the sign panel(s) from. I included a few pictures of this type of sign design which I am leading customers to more frequently. The aluminum cross beams match the posts and attach with machine screws firmly into each side. Wood posts require notching and heavy bolts, and you just never quite know for sure if everything’s going to stay nice and square after years in the weather. Aluminum post systems don’t have to dry; wood systems do and they tend to move a lot during the drying process.

Sixth, aluminum posts are much lighter in weight than heavy wood posts. This makes installing them easier and sometimes less expensive, especially if the signs are large and high off the ground. 

MAINTENANCE FREE POSTS WORTH CONSIDERING

So next time you’re having a sign designed for your business or organization, consider using painted aluminum posts!

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Mark Hackley owns and operates Augusta Sign Company in Staunton VA, serving Staunton, Waynesboro, Augusta County and beyond!  Contact him at 540-943-9818 for your next signage project.

Etched Glass Lettering

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Etched letters can add a touch of class to your entrance. Since the lettering does not stand out as well as regular opaque vinyl or hand-painted graphics, the uses are usally limited to places that want a subdued, yet classy look. That’s why I’ve used the etched vinyl material for the President’s office at a local university; the entrances to a craft brewery with a neat logo; the entance to the law office of a regional law firm.

There are a number of different types of etched vinyl, and of course my customers could opt for the real deal, actual etching into glass. I have priced genuine etched glass in the past, but have never sold anything, probably because it’s extremely costly.

Two types of etched glass films I use are readily available from my suppliers: Avery brand “Etchmark” and “Frosted Sparkle”. Etchmark is your basic etched look. The other has much more pizazz and intermittent sparkles throughout. I’ve also tried several Arlon films. One of those types was almost too clear and hard to see, especially when appled to the back side of the glass pane. Whether the vinyl is installed to the outside of the glass (first surface) or the backside (second surface) is the decision of the customer. To make a second-surface decal, I can tell my software to cut a mirror-image of the artwork, so then the adhesive will be on the graphics facing the glass when cut backwards.

If you have an occasion to use etched vinyl for your store windows and doors, let me know!

Carving Signs in Plywood

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Cheaper Alternative

Carving Signs in Plywood

Carving signs from plywood is less expensive than carving signs with cedar or redwood as the sign substrate, but will it last as long? The simple answer is probably not, but I have just started carving in plywood so I have yet to see how it will last out in the elements.

My experience with plywood signage tells me that, unframed, a sign made from plywood will begin to show signs of weathering within several years. An adequately primed and painted plywood sign should last at least five years is what I generally tell my customers, but it depends on UV exposure, edge exposure to moisture, sign colors, and whether the lettering is painted or cut vinyl.

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Unknown Durability

I am not sure how the carved lettering in plywood will fare when exposed to the Virginia elements. High heat and humidity in our area has a tendency to work on any exposed veneer joints where temperature can buckle the layers of the plywood allowing moisture to enter into the layers doing progressive damage. Cedar and redwood signs don’t have this vulnerability, thus the substrates will typically last a lifetime with regular maintenance.

I originally suggested a more expensive and durable carved cedar sign option, but unfortunately it was beyond the customer’s budget. That’s when the customer asked about carved plywood as an option. At first I wasn’t sure if that was even possible, but I soon discovered that it was doable. To create the same effect of a cedar sign, I had to laminate two 3/4″ pieces together since the thickest plywood I could get was 1″ thickness and carved cedar is typically made from 1 1/2″ thick boards.

Pleasing End-Result!

Once the sign was glued up, I took off the clamps, sanded, primed, and painted the background and graphics, adding several borders to make it more interesting. The customer suggested a white edge outline to help the sign pop from the green or brown-gray background, depending on the season. The customer replaced the old timber frame with new wood posts and beams. The protection from these extra large timbers around the sign edges should help the plywood panel fare better against the elements.

www.augustasigncompany.com-carved-plywood-signs-cedar-redwood-22980-24401-augusta-county-va

The customer was pleased with the final result! Now I will be sure to offer carving signs in plywood as an alternative to carved cedar for customer-candidates willing to compromise overall durability in their sign for lower cost.

Mark Hackley owns Augusta Sign Company near Middlebrook, Virginia in south-central Augusta County.

What are Prismatic Letters?

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Plastic Prismatic Letters on store sign in Waynesboro, VA

Prismatic letters are dimensional architectural letters that are typically used in building identification signage. Prismatic letters can be made of plastic, metal, or wood materials, and are the reverse of V-Carved letters, where if you imagine the inset V-carved lettering as a mold, the offset prismatic letters would be made using this mold, if that makes sense!

Sign craftsman and business owner, Mark Hackley laying out the prismatic letters on his shop table at his workshop near Middlebrook.

I recently had the opportunity to sell a set of molded plastic prismatic letters to a Waynesboro, Virginia retail customer. The customer utilized plastic dimensional letters to go along with his custom pyramid shaped logo on the entrance sign to his store off Main Street. The lettering was attached to a flat metal panel, painted flat black to match the wall finish, and was attached to the storefront over the main entrance. The sign panel to which the letters were attached was constructed using a 1″ thick aluminum tube frame. The two 30″ high X 7′ long, flat sign panels that held the prismatic letters were butted together in the middle and fastened to the frame with very high bond adhesive. I used my computer plotter to make the mounting pattern for the lettering. Holes were marked on the sign to match up with the female supports molded into the backs of each letter.

Dimensional Plastic Letters still packaged and ready to install on metal sign backer.

The lettering was attached to the sign panel with stainless steel studs and nuts, concealed behind each letter. The installation was fairly simple and took a crew of two only a few hours to complete, since most of the labor needed to fasten the letters was done in the workshop. This set of GEMINI brand prismatic letters came with a lifetime warranty which means that if any exterior letter or logo ever fades or breaks, they will be refinished or replaced at no cost: an important factor to consider if you’re a new business branding your building!

Prismatic type letters can also be made from wood. Western red cedar or mahogany, or redwood letters are routed, sanded, and finished in many options. One great option, but expensive, is 23 karat gold leaf letters. Gold leaf on prismatic lettering produces a tremendously eye-catching effect, and is great for brands wanting to convey elegance, high price items, or long-term stability. That’s why financial institutions, mainline religious groups, museums, and high-end retailers utilize this type of dimensional letter. Plastic and metal letters can also be gilded for special effect. But if you’re a new business or established business on a tight budget, formed plastic in standard colors are the way to go.

What are prismatic letters? They are a great way to add depth and attention to your business name. This project took less than a $2,500 investment from the new owner and he was able to finance the construction of the sign as part of his initial business venture’s loan package…and the letters will last a lifetime!

Mark Hackley owns and operates Augusta Sign Company which serves the Staunton, Waynesboro, Verona, Fishersville, and Stuarts Draft areas of Virginia in the Shenandoah Valley. Contact him at 540-943-9818.