3M sign graphics from Augusta Sign Company of Staunton, Virginia
From Hand-Painted to Computer-Cut
It’s interesting to consider what I’ve learned about lettering vehicles over the years. Although I am getting pretty old, at least I didn’t begin lettering covered wagons, or Ford Model T’s! But I did begin lettering vehicles before the Golden Age of Computer Graphics, when vehicles were still lettered with a paint brush and a can of paint.
Memories of a Signpainter
I remember doing my first fleet of vehicles for an electric company in Silver Spring, Maryland, Neary Electric, that used a neat and intricate letter style with red, white and blue inset elements in each letter, all done by hand using a hand-drawn and hand-pounced pattern that I made in my shop. The year was about 1986 or 87 when I still resided in Maryland. When I moved to Waynesboro, VA a few years later I continued to travel to Silver Spring to letter new vans for the company for a little while.
Avery Vinyl Branding
New Age Dawns
After the computerized plotters became commonplace, it just didn’t make a lot of sense to hand letter trucks any more. The many advantages of using vinyl graphics for vehicles easily outweighed paint: First, red vinyl lasted much longer than a few years out in the UV rays from the sun like sign paint did. Back then it was good if you used a 5-7 year vinyl product, but nowadays a 10-year lifetime is the new standard for cast vinyl sheeting. You may wonder what cast vinyl is? There are two types of sign vinyls, cast and calendered.
A Lesson on Vinyl Types
Cast films are considered the industry premium. These films start in a liquid state with the ingredients blended together and then poured onto a casting sheet. The casting process produces a thin gauge film—usually 1- to 2-mil thick. By casting film on a sheet, the film stays in a more relaxed state, resulting in a durable, flexible, conformable and dimensionally stable film that retains color well. These films are ideal for complex surfaces such as vehicles and where a smooth finished look is expected. The expected life of cast films can usually reach 10 years before any discoloration or adhesive loss begins!
Calendered films are often called intermediate or short-term films. They start with a molten mixture that is extruded through a die and fed though a series of calendering rolls. The rolling and stretching process produces thicker films (3- to 4-mil is common) that have some inherent memory, making the film less dimensionally stable and less conformable with a tendency to shrink when exposed to heat. However, they are less expensive, somewhat more scratch resistant, and their heavier weight makes them easier to handle than cast films. These films are well suited for flat and simple curved applications on a variety of substrates. Expected lifespan of calendered vinyl films outdoors can range from about one to six years.
Let’s Wrap It Up
Today, wrapping vehicles is the new trend, and it makes an effective statement out there on the roadways of the world. I tend to shy away from full vehicle wraps and focus on vehicle graphics projects that don’t involve fitting the vinyl films over complex vehicle contours, which is very tricky. I stick with simplified vehicle lettering jobs. I have the capability to take photos of each side of the vehicle and superimpose the graphic designs onto each sign on customer proof drawings. That way the client can see exactly how the graphics will be integrated into the vehicle before the project begins.
background surfaces.
Good Advice
I am able to letter vehicles up to a standard van size in my workshop garage bays. Anything larger I usually tackle at the customer’s lot or garage. Simple designs are usually one day projects, but more detailed designs may take 2 or 3 days to complete. It’s usually a good idea to stick with one sign company to letter your vehicles if you have a fleet. That way you can be assured that the designs and colors are consistent. Branding your vehicles is one important element of a well-branded company.
If you have new vehicles that need lettering or old ones that need re-branding, contact Augusta Sign Company, serving Staunton, Waynesboro, and Augusta County, and neighboring areas, with quality vehicle lettering services.
Mark Hackley owns Augusta Sign Company, 540-943-9818
It takes some planning to make and install a large free-standing sign in the ground and install it where everything is relatively level and plumb. 
tables, disassemble them, then assemble them again in the field when I know that everything will fit together nice and square. Most of the time the land in which the sign will be erected is not flat, so I have to take into consideration that either one hole will be deeper or one post will be longer to compensate for the difference. Once the holes are dug and the poles are hoisted in place, I attach my own clamping system, one of Augusta Sign Company’s ingenious intellectual properties, that keeps signposts plumb in both directions (forward-to-backward; and side-to-side).
Applying Gold Leaf to Carved Signs
presented my proposal, she elected to go for the gold! Gold leaf is an ancient art form. “The Temple of Solomon was profusely gilt,” says Homer in his early writings. Gold leaf was widely used in old Roman art, architecture, furniture, and carved lettering. Gold leaf is actual gold that is beaten down to a fine sheet and applied to surfaces with “size”, a special type of “glue” that the thin metal sheets stick to. To make the sign for the horse farm, I first ordered the cedar panel and had the letters and borders CNC-routed from my customer-approved design. Once the letters and borders were carved, I sanded them with fine-grit sandpaper to smooth out any course grain in the lettering. Once sanded, I cleaned and primed the entire two-sided sign with a quality oil-based primer that seals the wood and provides an adequate base for the finish coat, which in this case was a brush-painted Hunter Green sign enamel. It helps to tint your primer to the shade of your finish coat, so I added some black tint to make a gray primer coat. I use the 2-2-2 method in my finishing of wood signs: 2 coats primer, 2 coats background finish, and 2 coats for the graphics, which for this project meant two passes of gilding to catch any missed areas and pinholes.
Once the gold was applied and cured for several days, I burnished it with a cotton ball and completely waxed the entire sign using Nu-Finish synthetic auto wax, available in most auto parts stores. The post was constructed from a 6″ X 6″ X 13′ long Southern Yellow Pine column with a beefed-up area at the bottom of the post, suggested by my customer’s architect. The sign post was colored black to match the black iron scroll bracket, which was a stock item from my supplier. I used stainless steel eye-bolts and quick links to attach the sign to the bracket. The sign was planted in a 3 foot deep hole and surrounded with fast set concrete.
Virginia only has seven cities with populations in six figures. Most of it’s cities and towns fall between about 5,000-75,000, with about 10 over and about 120 under. Most of the towns in the Shenandoah Valley, where my shop is located, are perfect places to hang interesting, hand-painted wood signs. And it so happens those are exactly the types of signs I make in my shop near Staunton, Virginia!!
adhered to the flat surface, then wherever the stencil does not cover the wood, it is blasted away using a high-pressure sand gun. Various size nozzles are used for different effects. After blasting, the signs are stained with a high-quality, durable solid-color oil stain, then hand-lettered. These signs are very long-lasting and can be easily maintained with scheduled periodic annual cleaning and refresher coats of paint every decade. The sign pictured above for Waynesboro Florist was put into service in the mid-1990’s and is still looking great with only one 
maintenance call a few years ago, where I rehabbed the fading paint.
Hanging the signs is usually accomplished using iron scroll brackets and chain with hooks. There are several standard bracket types in use, and brackets can also be customized for a much higher investment. Probably one of the biggest things to remember about quality wood signs is their regular maintenance. Just as a great musician would tune her piano on a regular basis to ensure good quality sound, a great business owner would clean, re-stain, and repaint her sign periodically. The rule of thumb for signs manufactured by Augusta Sign Company is every about 5-10 years. The cedar and redwood and mahogany boards themselves will last a lifetime with no maintenance, but the branding that is painted on the signs will have to be periodically refreshed to keep up a positive image.
Call Mark Hackley, founder of Tree Street Signs that later became Augusta Sign Company for all your downtown signage needs. Not only can he help you with wood identification signs, but also door and window lettering, wall lettering, banners, and other temporary advertising signs like sandwich boards that you’d use in marketing your awesome downtown shop. He can be reached at 540-943-9818.
interior, there is an assortment of materials you can use that are potentially less expensive than those that have to withstand the elements for many seasons.
recommended for exterior applications. The particular style used had black edges and brushed silver laminated metal faces. They were stud mounted with spacers to cast a nice shadow from the office lighting. The customer painted the accent wall themselves and the rich blue background really sets off the lettering and makes for a very eye-catching branding statement!
THE GREAT OUTDOORS
show how your letters will look an the wall? Do they provide final proofs for approval prior to production? What is their turn-around time? All Gemini letters and plaques come with a lifetime guarantee, another good reason to specify the Gemini brand, as do many architects.
The most common options for exterior wall letters: Cast aluminum or bronze with natural satin finished or cast aluminum with painted finishes; Cut out aluminum with either natural or painted finishes; Cut out acrylic letters with painted finishes. All these types of letters are the best for walls.