Layering multiple parts

[Awesome]

I've cut signs for people before that they wanted layered... background one colour and top another colour. We did some hitch covers a few years ago as well. We always ended up drilling a hole behind the top piece and then doing a plug weld to hold the top layer on. This, of course, ruins the paint or powder coat on the top piece.

There were two times when we tried using JB-Weld, but that ended up making a huge mess and the customer wasn't happy with the result.

How do you guys layer metal for making more complicated signs? For example, the "Felon 47" sign that I saw posted in the members-only section up at the top. How would you go about attaching the backing pieces to the top piece?

I've used pop rivets before too, but those are ugly and don't work for everything.

[Joe Jones]

Plot synchronized holes through all layers.

Top layer - Run a rod through and tack weld the top. Sand FACE flush and paint.

Layers 2 through ? - Paint as needed.

Bottom layer - Paint as needed. Run rods through all holes and "sandwich" the layers. Bend rod 90 degrees where it pokes out of the back piece. Clip short and tack weld to rear of bottom layer and grind ALMOST flush. Touch up paint on rear. Tack weld on back side of rear piece is not seen from the front because of other painted layers on top of it.

Alternate termination - Bend rod 90 degrees and clip. Place a ball of JB WELD around rod that pokes out of back side. Cure, grind down to a button to hold rod end.

Joe

[ROKCRLER]

How do you guys layer metal for making more complicated signs? For example, the "Felon 47" sign that I saw posted in the members-only section up at the top. How would you go about attaching the backing pieces to the top piece?

I used rare earth magnets on this one.
Epoxy/glue magnets to the top piece and done.
The thickness of the magnets adds depth to the piece.

PXL_20240611_221044112.jpg

[Joe Jones]

The thickness of the magnets adds depth to the piece.

Interesting! I wonder ... could one use SUPER GLUE to place rare Earth magnets at hidden locations, and then put a drop onto each magnet before placing the next layer on top? This would result in a dimensional piece that uses NO BOLTS!

Hmmm ... I will have to try this!

Joe

[ROKCRLER]

This piece uses glued and loose magnets to change/rearrange the words.
The outer ring holds the LED's all they were bolted around.

180330 (1).jpeg

[Awesome]

Great ideas, and none of them were things I had considered. Thank you.

[djreiswig]

Could weld a nut (or a coupling nut if you want a larger space) to the back of the top layer and screw a machine screw from the back of the bottom layer. Kind of like how circuit boards use standoffs.

[ROKCRLER]

That's what I used on the one above