Ghost of Spookie,
I have a corner yard and yes, the Circus was on a small part of the side yard and the main entry was in front. As for the wooden posts, they're all dropped in the ground about 22". I found a bunch of long pallets with 10' timbers and cut them apart. We have real good soil, so digging the holes with a small post hole digger went quick.
Making the open channel lettering wasn't too difficult. I found a font I liked, projected the below image on some scrap plywood, traced and cut it out. For the flashing, Lowe's sells 6" x 10' rolls. I made a miter box to hold it and cut 2 rolls in half with a Sawzall. This gave me 40' of 3" flashing. The sign used 30'. Using the wood as the form, I shaped it to fit. Where the metal has sharp bends, I used a piece of wood cut in a triangle to fold over. I attached the metal to the plywood with a brad nailer and where the metal came back together, I used two aluminum rivets. After brushing the inside with a thick white primer, I sprayed the inside with Rustoleum Colonial Red and the outside with Rustoleum Gold Rush. For the lights, I simply eyeballed light locations and drilled. (I prefer a less than perfect look) The part that took the longest was taking apart a new cord set and relocating all the sockets to eliminate any extra cord between each bulb. The 8' rails that hold the letters are a gray composite lattice edging for plastic lattice. It's available at the home centers.
![Tree Plant Flower]()
![Wood Font Number Plywood]()
![Nose Wood Tree Leg Table]()
![Font Number Rock Mural Art]()
![Font Text Poster]()
I know you probably used the factory edge of the flashing for the part of the letters that faced outward, but I'm really curious to know how clean of an edge were able to get with the sawzall?
