Making
magnetic signs in your garage or shop not only profitable
--
it can be fun! Magnetic signs are vacuum formed, 3-D sheets of
plastic
with two-way foam or magnetic strips on the back to hold
them
in place.
The
"book" on magnetic signs has not yet been finished because
each
every new entrepreneur discovers new innovations, such as
"cast
iron" finish or metallic paints and relief cameos. The
primary
products, magnetic car and truck signs, are widely
accepted
but there is still plenty of room for your creative
talents!
The
initial investment to go into this business is approximately
$1,000
for some basic no-frills equipment and startup supplies.
The
cost of making a pair of 12 x 24 inch (the standard size) is
about
$7.00 with 10 -15 minutes labor. A pair this size sells for
about
$40 ($24 wholesale).
The
magnetic sign process is performed by placing a 28 by 16 inch
start
white vinyl plastic into a vacuum machine, heating the
plastic
until it softens, then "pulling" it down over an
arrangement
of letters with a vacuum pump.
The
vacuum machine looks something like a suitcase -- with
heating
wires in the top perforated baffle about 4 inches below
the
rim of the bottom. The vacuum motor is underneath the baffle
and
the controls are on the outside front. The plastic is laid
across
the bottom half and sealed when the lid is closed.
The
heat is turned on a couple of minutes (until the plastic
begins
to sag), then it is turned off and the seconds, during
which
time the plastic is pulled down onto the perforated baffle.
When
the vacuum machine is opened, the resulting sign has a
raised
impression of whatever design was placed on top of the
baffle.
The rough sign is then removed, trimmed, magnetic tape
applied,
and the raised portions are "painted" with rubber
rollers
(brayers) and vinyl "ink" (Paint). Minor errors are
scraped
off with pocket knife and PRESTO, a finished magnetic
sign!
The
magnetic sign "art" is fashioning and arranging the models
(letters,
logos, etc.) that create the sign. Letters and logos
are
about 1/8" thick (thicker for large items). They are arranged
or
laid out exactly as the sign should appear.
A
wide variety of letters (sold in sets or "fonts"), Logos and
various
special effects such as borders, corner embellishment and
arrows
are available commercially in magnetic, metal or
composition
material.
Magnetic
are the most expensive and are used for designs laid out
directly
on the baffle. Their magnetism helps them stay in place
as
the hot plastic forms over them. Metal letters are also
expensive,
but long lasting. Composition letters are used for the
clipboard
process (see below), and are quite easy to make
yourself.
There
are two basic methods of laying out copy. The first (and
fastest)
is to arrange magnetic letters directly onto the baffle
and
"pull" the sign down over them. This method, however, often
results
in slippage -- letters on the outside are moved slightly
as
the plastic catches them in the pulling process. It also is
difficult
to keep everything "together" for more than a couple of
pulls.
Other
drawback are the cost of magnetic letters, that only the
old,
two-way cellophane back magnetic tape can be used (foam
backed
would melt) and, that the baffle holes show through onto
the
sign (although few customers seem to mind).
The
other, (chipboard) method involves gluing magnetic OR ANY
OTHER
TYPE LETTER or design onto pieces of chipboard that are the
exact
size of the desired sign.
Chipboard
is a gray composition material like that found on the
back
of writing tablets -- its is porous enough to let the vacuum
process
work, and smooth enough to give the sign a nice, satin
finish.
Most
sign operators have many different styles of chipboard
patterns
-- all cut to shape, with rounded corners even custom
shapes.
Lines are drawn on them with FELT TIPPED PENS ball point
leaves
lines that show on the sign!) as layout guides.
Some
even have circular lines so the letters of top line of the
sign
can be laid out in an arch. As the letters are placed onto
the
chipboard pattern, a touch of glue is added (white, or
gluestick),
to hold them in place (use more glue for more
impressions).
Once the sign is laid out, place the whole thing in
the
machine and make as many signs as you need.
When
finished, pick off the letters and use a piece of sandpaper
to
smooth the remaining glue on the chipboard. Occasionally, you
may
have to wash the letters -- but not often.
Chipboard
signs do not show the tape lines because the tape is
applied
after the sign has been formed. They are especially
desirable
in cases where several sets are needed -- and for those
little
space-fillers, because the letters stay in place. They
also
offer the advantage of custom shapes. Any shape you can cut
out
of the chipbaord can be the shape of your sign, which can be
used
over and over again (thanks to the sandpaper technique).
Finally,
the chipbaord sign is now every bit as durable, due to
the
advent of foam backed magnetic tape.
Several
years ago there were problems with the magnetic tape
coming
off, even for signs molded in the machine (where the tape
and
plastic are hot when they "meet").
This
problem was sometimes caused by improper molding or the use
of
mold release spray in the area. The proper way is to frame the
desired
sign on the baffle with the magnetic tape, then pull off
the
protective cover at the last moment before the sign is
pulled.
Signs made this way show both the baffle holes and the
magnetic
tape impression.
Signs
not made this way (e.g.,chipboard) should ALWAYS have foam
backed
magnetic strips or full magnetic backs. Otherwise, there
will
be detachment problems.
Full
magnetic back material costs about twice as much as strips
and
is half as thick. It does make a nice, sturdy sign, but
probably
won't last any longer or perform any better!
Some
sign makers use styrene plastic sheets, which are much
cheaper
than vinyl (or clear butyl) -- but they will not last
outside.
Styrene should be use for experimentation, molding and
inside
signs only. It is wise to keep a few sheets around for
these
purposes.
Note
that styrene will not stick to vinyl and vice versa. Styrene
works
fine for molding and will keep for months if kept flat and
out
of the sun. Many sign makers keep impressions in styrene in
case
they need to mold more letters or logos.
There
are several ways to mold your own letters and logos. You
can
mold from impressions you make, or copy one from another sign
(clean
the back and spray it lightly with mold release first).
Although
you can use temporary material, such as fiber glass,
most
of these will not hold up in the vacuum machine for more
than
one or two pulls (due to the heat), and some will require
lots
of mold release (or baby powder).
Molding
compound (two part) is expensive, but yields very
inexpensive
fonts. If you want to save money, buy a font of
PLASTIC letters, make an impression of them in
styrene, then
mold
your own letters with a good quality molding compound. You
will
be able to save about 85%!
Another
way to save money is to make your own models out of
Masonite
or chipboard (two ply). You can make arrows, lines,
flowers,
whatever (#8 copper wire makes excellent parentheses;
model
airplane balsa strips are great lines and boxes).
If
you want more copies, make an impression in styrene -- or
unused
portion of a sign that you are pulling -- and mold as many
as
you need.
Selling
magnetic signs is a matter of getting out the word. If
you
want to wholesale, take a few (small) samples around and call
on
stationery stores. Tell them about your service and how long
it
will take to get a pair of signs they order (since you are
local,
you can beat out-of-towners).
When
they agree to take orders, leave a price list and your phone
number.
If you also retail, you must sell at the same "suggested"
retail
prices (or your accounts will leave you flat). Put signs
on
your truck or car (sides and back), a small ad in the paper,
and
have a few cards printed.
Set
up a record-keeping system, get some sales books from the
dime
store (stamp them with your company name), and start
cranking
out signs.
Although
anyone can learn to make magnetic signs, the best advice
is
to get an outfit, invest in some styrene and an 8 oz bottle of
styrene
paint, and "ruin some plastic."
It
takes a little practice to become proficient at spacing
letters
and painting the rollers, etc. but you will catch on
surprisingly
fast.
An
easy way to keep track of orders that come in by phone
(usually
from retail accounts) is to keep a bound notebook next
to
the phone, and make a little box beside each order.
List
the date, account and full details of the sign ordered. When
the
order is finished and delivered check off the little box --
this
will let you see at a glance which orders are still pending
at
any one time.
The
biggest potential problem area is that you might make
mistakes
that result in lost time and money.
Make
sure all of your "copy" is written down and keep a
dictionary
handy. When taking orders by phone, be especially
careful
to get the correct message, spelling, colors, etc.
When
laying out the work, pin the order at eye level above where
you
are working -- and double check the sign against the order
before
putting your finished layout into the machine... If there
is
the SLIGHTEST doubt in spelling or wording, check before you
pull!
One
other thing be aware of is the size of your vacuum machine.
The
standard sign is 12 x 24", so your machine should be big
enough
to make one OR TWO signs at a time. With
odd sized
machines,
you may have a lot of expensive waste.
Tip:
If you consider buying a second machine, get one that will
use
the same size rolls of plastic, so you can buy in bulk and
use
the same cutting boards, etc.
You
can also make customized plates in a standard vacuum machine
( 3
at a time in a 12 x 24 inch model). This simply requires
three
chipboard patterns upon which you lay out and glue the
desired
copy. And, you can make impressions of almost anything.
One
sign maker glued bolt heads on his chip board and painted
them
so the sign look like they are bolted on the vehicle!
Another
trick is to cover the chipboard with fabric (use 3-M
spray
adhesive for this) for an interesting background. There are
thousand
of other variations that you will discover in this
fascinating
business.
Note
also that once you are in the magnetic sign business, the
same
customer will be interested in printing, engraved signs, and
all
sorts of things that are associated with starting and
promoting
small businesses.
Tips:
to make "metallic" paint, add an ounce of aluminum to seven
ounces
of regular color. For a cast iron appearance, form over
sandpaper,
paint black and apply metallic rub 'n buff.
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