An outdoor sign is an effective way to draw attention to your business, advertise products or services, disseminate information, or display visual art. With the right materials and techniques, you can create a customized, durable outdoor sign to suit your needs. This comprehensive guide covers how to make different types of outdoor signs from start to finish.
Planning Your Outdoor Sign
The first step in creating an outdoor sign is planning. Consider the following factors:
Purpose
What is the purpose of your outdoor sign? Common uses include:
- Business signage – Identify your company, convey your brand
- Advertising – Promote products, services, events
- Wayfinding – Provide directional or locational information
- Artistic – Make a visual statement or public art display
Location
Where will the sign be situated? Sign placement impacts visibility, size needed, and material/construction choices. Outdoor locations include:
- Building facades
- Fencing or posts
- Free-standing sign frames
- Vehicles
- Windows
- Parks, sidewalks, trails
Size
Determine the appropriate size for visibility. Larger signs can draw attention from further away. Consider:
- Viewing distance
- Space limitations
- Any size restrictions (check local regulations)
Materials
Select durable, weatherproof materials suited to the location:
- Wood – Classic, affordable, requires weather protection
- Plastic – Lightweight, low maintenance
- Metal – Durable, versatile for shapes/sizes
- Neon – Visually striking, ideal for bright colors
- Paint – Budget-friendly but less durable
Design
Plan the layout, text, graphics, colors, and stylistic details. Tailor the design to your purpose and preferences.
Budget
Factor in costs for materials, hardware, production, installation, and upkeep/maintenance. Setting a budget helps guide material and design choices.
Regulations
Check local ordinances related to sign placement, size, materials, lighting, etc. Permits may be required.
With planning and preparation, you’re ready to start constructing your custom outdoor sign!
Building a Wood Sign
Wood is a traditional, attractive sign material with an artisanal look. Follow these steps to make your own wood sign:
Select the Wood
Choose weather-resistant wood like cedar, redwood, cypress or pine. Plywood grades CDX or marine-grade also work well. Standard thickness is 1⁄2 to 3⁄4 inches.
Cut to Size
Measure the planned dimensions and cut the wood with a circular saw or jigsaw. Wear safety glasses and mask.
Sand and Clean
Smooth any rough edges by hand-sanding. Wipe wood with solvent to remove dust and oils.
Apply Primer/Sealer
Use an exterior wood primer and sealer for a protective base layer. Allow drying per product directions.
Add Design Elements
Paint background colors and lettering by hand with exterior-grade acrylic paint. Or use a vinyl cutter to apply vinyl lettering and graphics.
Finish with Clear Coat
Brush on 2-3 layers of exterior polyurethane or spar varnish. Let dry fully between coats. Adds protection from weathering.
Install Mounting Hardware
On the back, attach hanging loops, angle brackets, or another method to mount the sign.
Mount Sign
Secure to the chosen outdoor surface. Check that mounting hardware is anchored into a solid base material using appropriate fasteners.
Maintain the sign by checking for damage, repainting faded areas, and re-applying clear coat every 2-3 years.
Constructing a Plastic Sign
Plastic is lightweight, weather-resistant, and easy to work with. Follow these steps to create a plastic outdoor sign:
Obtain Plastic Sheeting
Good options include PVC, acrylic, polycarbonate or plastic-coated aluminum composite sheet. Select 1/8 to 1⁄4 inch thickness.
Measure and Cut
Measure planned dimensions and cut using a table saw with fine tooth blade or a circular saw. Wear protective gear.
Drill Mounting Holes
Drill holes in the corners or edges to accommodate mounting hardware. Place protective backing so holes are neat.
Design and Decorate
Like wood, plastic signs can be painted or vinyl designs applied. LED lights can also be inset into plastic.
Add Supports
For large or heavy signs, adhere plastic or aluminum support strips to the back using exterior-grade silicone adhesive. This prevents sagging.
Install Mounting Hardware
Attach hanging brackets, angle supports, or a post mount on the backside by bolting or screwing into the pre-drilled holes.
Mount Sign
Affix securely in the desired outdoor location, verifying any posts or structures will safely hold the sign’s weight.
Maintain
Wipe clean as needed. Touch up paint or replace vinyl as it fades over time.
Plastic is low-maintenance for outdoor usage, though may show scratches or color fading faster than wood or metal.
Making a Metal Sign
Metal provides a sleek, modern look and is highly durable for outdoor signs. Follow these tips for creating one:
Choose Metal
Aluminum and galvanized steel are affordable, lightweight and corrosion-resistant. Stainless steel offers superior weather-resistance.
Measure and Cut
Measure planned size and use an angle grinder or plasma cutter to cut metal. Wear eye protection and gloves – metal can be sharp.
Grind/Sand Edges
Use an angle grinder or sanding block to smooth any rough edges. Be cautious of sharp metal debris.
Clean Surface
Wipe down with solvent to remove oils or residue from cutting and prepare for painting.
Prime and Paint
Apply exterior metal primer, then spray paint with your background colors and lettering using exterior-grade spray paint. Allow proper drying time between coats.
Add Vinyl or Illumination
If desired, apply cut vinyl graphics. Also can inset LED lights into metal for illuminated signage.
Install Mounting Hardware
Bolt or weld brackets, posts, or other mounts to the backside for hanging and securing the sign.
Mount Sign
Affix to exterior surface, verifying adequate load-bearing capacity for the sign’s size and weight.
Metal requires little maintenance beyond occasional touch-ups to paint. It withstands weathering very well.
Constructing a Neon Sign
Neon signs involve bending glass tubing and filling with gas to create vibrant colored lighting. To make your own:
Plan the Design
Neon signs involve complex bending and wiring. Either follow an existing plan or create your own minimalist design. Consider hiring an expert for custom neon.
Gather Tubing and Supplies
Purchase neon tubing in desired colors, transformer, wiring, electrodes and other electrical components from a specialty store.
Shape the Tubing
Use a bending tool or tube bender to gently and gradually form the glass tubing into the planned shapes and letters.
Connect Electrodes
Attach an electrode at each end of the tubing and wire to the transformer to complete the electric circuit.
Purge, Test and Fill
With tubing open at one end, purge impurities using a vacuum pump. Test for leaks then fill with neon, argon or other gas mixture and seal tube.
Wire and Mount
Wire the tubing to the transformer and mount securely behind plastic sign face. Ensure wiring is properly insulated.
Install Sign
Affix the completed neon sign in desired location on exterior of building. Ensure it is safely situated away from pedestrian traffic and protected from weather.
Hire an electrician if unsure of any wiring steps. Neon signs require care when handling and electrical knowledge. But offer a classic, vibrant look.
Painting an Outdoor Mural
Large painted murals and graphics are an eye-catching outdoor sign option. Follow these tips:
Select a Wall Space
Look for a blank exterior wall section with ample space for your planned mural size. Consider visibility and lighting.
Clean and Prepare Surface
Power wash the wall and use a wire brush to remove loose paint or materials and create texture.
Outline the Design
Sketch out the mural design first with chalk or temporary paint. Tweak until satisfied.
Paint the Background
Using exterior house paint, paint over the wall area with your desired background colors.
Paint Graphics and Lettering
Use exterior acrylic paints to hand paint the details, images, text and other features. Allow proper drying time between layers.
Add Clear Coat (Optional)
Once painting is complete, apply 1-2 layers of clear exterior sealant. This adds protection from weathering.
Maintain the Mural
Touch up paint chipping and fading as needed over time. Expect to fully repaint murals every 3-5 years.
Research local regulations, as some communities require permits for public murals even on private property.
Installing Vinyl Signage on Vehicles
Vinyl wraps and lettering make customized signs on vehicles for businesses, events or personal uses. To apply:
Clean the Vehicle Surface
Wash and completely dry the vehicle area to apply vinyl. Wax or coatings can interfere with vinyl adhesive.
Measure the Area
Determine exact measurements for the vinyl elements and overall design. Include a bleed margin.
Print and Cut Vinyl
Upload design to vinyl printer/cutter service or order pre-cut vinyl lettering. Ensure proper outdoor grade vinyl is used.
Mask Surrounding Areas
Cover vehicle areas not getting wrapped with painter’s tape and sheets to protect from overspray.
Apply Background Color (Optional)
If the design has colored background, apply exterior automotive spray paint and let fully cure per directions.
Position Vinyl Elements
Remove backing and carefully align vinyl on vehicle surface, pressing gradually from center outward to affix.
Heat Shrink With Heat Gun
Use a heat gun to gently warm and soften the vinyl, shrinking it taut to curves and edges as you work across.
Clean Up Edges
Trim any vinyl overhangs with a razor. Rub edges firmly to maximize adhesion. Remove masking materials.
Seal With Clear Coat (Optional)
For added protection, apply 1-2 layers of automotive clear coat over vinyl design.
Vinyl vehicle signs typically last 5-7 years outdoors. Heat, sun and wear require occasional replacement.
Installing Window Lettering and Decals
Add visual interest to glass windows and doors using these application tips:
Clean Glass Surface
Clean window thoroughly with glass cleaner to remove dirt, oils and residue. Let dry completely.
Measure Area
Measure the glass to determine size for images, text, and any background shapes. Account for uneven surfaces.
Print or Cut Out Design
Use pre-cut vinyl lettering or a vinyl cutter to create decals. Or hand paint/stencil letters onto temporary adhesive.
Remove Backing
Peel off the backing from the vinyl or adhesive material, keeping the decal face up.
Position Decal on Glass
Carefully place decal in position on the glass and press down at the center first, smoothing edges outward.
Squeegee Out Air Pockets
Starting at the center, use a squeegee or credit card to smoothly apply pressure and push out any air bubbles.
Clean Edges
Trim any overhanging vinyl edges carefully with a razor. Wipe perimeter firmly.
Optional Finishing Coat
For longevity, apply 1-2 light coats of clear enamel spray paint over the decal.
Check local codes, as window signage may be limited in size or placement for safety. Expect to replace window decals every 1-2 years due to sun exposure.
Hanging a Banner Sign
Banners make very visible and affordable outdoor signs for short-term use. Follow these tips:
Select Durable Banner Material
Vinyl, canvas, mesh and polyester fabrics work well. Consider treating with weatherproofing sprays.
Decorate the Banner
Use cut vinyl designs, fabric paint and markers to decorate the banner. Sew fabric appliques if desired.
Finish the Edges
Fold and sew the edges for a clean hem and to reinforce seams. Grommets also help strengthen banner edges.
Add Grommets
Spacing grommets every 12-18 inches around the perimeter allows the banner to hang flat and attach safely.
Determine Mounting Method
Consider poles, spaces between buildings, fences or lashing to structures. Ensure a secure mounting that can withstand winds.
Install Banner
Attach banner to selected area using zip ties, strong rope/cord or hooks through the grommets. Use several attachment points for large banners.
Maintain and Repair
Monitor for tearing, loose hardware or fraying seams. Remove and patch or re-hem as needed. Replace grommets if they break or pull out.
Vinyl and synthetic banners can typically last 6-12 months outside. Replace when faded or worn.
Creating Signs with a CNC Router
For production of multiple wood or plastic signs, a CNC (computer numerical control) router efficiently cuts shapes and lettering to consistent quality. The process:
Design the Sign Digitally
Create the sign image and lettering in a vector graphics program. Convert text to outlines.
Select Material Stock
Choose the type of wood or plastic sheeting, in proper dimensions for CNC machine.
Set Up and Program CNC Machine
Load design file into CNC software paired with machine. Specify tool paths, speeds/feeds, material size and other parameters.
Secure Material in Machine
Align and tightly fasten the stock material on the machine bed to prevent shifting during routing.
Complete Trial Run
Do an initial trial pass on scrap material to ensure proper machine setup before routing actual signs.
Route the Signs
The CNC follows the programmed tool paths to cut away material and create the sign design and lettering outlined.
Apply Finishing Touches
Sand edges, paint, add hardware for hanging, etc. to complete the signs.
CNC routing provides consistent precision and speeds production of multiple identical signs.
Installing Lighted Signs
Illumination draws attention plus allows sign visibility day or night. Here are tips for lighting:
Select Lighting Method
Lighting options:
- LED strips or modules
- Bulb string lights
- Individual spotlights
- Neon tubing
- Luminous paints
Plan Wiring and Power
Determine wiring schematics and power supply needed for chosen lighting type and sign size. Hire an electrician as needed.
Incorporate Lighting in Design
Allow space to mount strips or lights. Position to evenly light the sign. Highlight key text or graphics.
Add LED Strips
Peel backing and firmly press LED strips into position on sign backing/frame using adhesive.
Connect Wires to Power Source
Run wiring neatly along edges or mounting structure. Connect to transformer or electrical supply, verifying adequate power.
Test Lighting
Double check all connections then test that the lighting illuminates properly before fully mounting sign.
Maintain Lighting
Replace any failed bulbs or LEDs promptly. Check wiring connections. Use weatherproof wire nuts and conduit.
Ensure compliance with electrical codes and proper installation of outdoor wiring. Well-lit signs attract attention!
Common Outdoor Sign Materials Comparison
| Material | Durability| Cost | Appearance | Notes |
|-|-|-|-|-|
| Wood | Moderate | Low $$ | Classic, natural | Requires protective finishing and maintenance |
| Plastic | High | Low-moderate $ | Modern, sleek | Won’t rust. Can crack over time |
| Metal | High | Low-moderate $$ | Industrial, edgy | Prone to rust if unprotected |
| Paint | Low | Low $ | Handmade aesthetic | Fades faster than other materials |
| Neon | Moderate | High $$$ | Vibrant, retro | Requires special bending skills and electrical knowledge |
| Vinyl | Moderate | Low-moderate $$ | Wide range of colors/finishes | Eventually wears and fades |
Outdoor Sign Frame Options
- Freestanding sign stands
- Building facades
- Fence or rail mounts
- Pole mounts
- Ground stakes or spikes
- Roof mounts
- Projecting/hanging brackets
- Adhered to vehicle surfaces
- Window clings
Safety Tips for Outdoor Sign Projects
- Use caution when operating power tools and equipment – follow proper safety procedures. Wear eye and hand protection.
- Take precautions when working at heights, on ladders or lifts.
- Hire an electrician for any complex wiring needs.
- Check for underground wires, pipes or other hazards before digging holes.
- Obtain necessary permits and follow local sign codes.
- Use assistants for lifting or steadying large signs during mounting.
- Ensure signs are securely fastened and mounted into solid underlying structures.
Maintaining and Updating Outdoor Signs
- Check for damage after major storms.
- Repair cracks, dents; replace broken hardware or supports promptly.
- Clean surfaces regularly with appropriate cleaners.
- Touch up paint and finishes as they fade or deteriorate.
- Update changeable elements like letter boards routinely.
- Plan for full sign refurbishment or replacement every 4-8 years.
Key Takeaways
- Plan your sign’s purpose, placement, size, design, materials and budget.
- Select durable, weatherproof materials suited to the sign type and location.
- Prepare surfaces properly and use primers, sealers and exterior-grade paints/coatings.
- Allow adequate drying time between finish coats.
- Make sure sign has adequate structural support and is securely mounted.
- Account for accessibility and visibility in sign placement.
- Check local regulations on sign codes and restrictions.
- Maintain outdoor