i thought i'd start a thread where we can share sign building techniques, tips & tricks.  i like learning how things are made, however i don't have much personal experience with building signs myself.  i know we have members here who have professional experience, so i figured we could have a space to collectively improve our skills as a community.
im a visual person and videos are especially helpful to me.  YouTube maker Wesley Treat occasionally posts sign build videos (not to mention other neat non-sign builds), that i find informative.  this is his latest one, and it shows metal work, masking, painting, artificial weathering/aging, wiring, assembly, etc.

Hey Neon Preservation! Great idea, and great topic for a thread! That's a cool video. I guess if you are going to make metal sign cans, it helps to have all the right tools for the job, which it looks like that guy does. :)  I don't typically make big signs like that, so it's interesting to see a lot of that process. I mostly use wood and Sintra (pvc sheet) for the signs I make, which are usually no bigger than 3 or 4 feet, and I make the occasional skeleton (dead) frame for window signs. I did make a rather large sign (for me) a few years ago which was approximately 2'x8' and built the frame from wood which probably made it a lot heavier than it needed to be, but since I don't have the right tools (or knowledge) to build a metal can, I had to go with what I knew.  I love the idea of making videos that show the process, but am discovering how time-consuming they are to make! I don't really have anything specific to say about sign building, but I'm hoping someone else chimes in!

This is a great forum idea!  For me, it depends on what you're doing exactly. If you have the specs, space, and equipment for bigger signs, welding and alumiunum are your best friend. Structurally, Steel is your friend. Outdoor signs; non rusting hardware is your friend. I like to do that, but if making smaller artwork, I like cutting aluminum and shaping it together without any welding or glue to hang in personal homes.  I'll try to post an image if I can find one.

I also love using pvc for cleanliness and ease. But I believe its wasteful from an environmental standpoint. I like wood and recycled materials as well. I think every job entails a different approach.

Love this video. Gorgeous sign- well done! Sheet metal is amazing... but steel is so heavy- I do prefer aluminum :).  I have made some channel letter signs before- processes pretty similar. SO much work. 

I do miss making things all nice like that. In NYC so much of the work is disposable- CNC machines and auto channel letter CNC benders reign supreme. I wonder just how tight the CNC machine can cut vs the knotcher... 

Housings are "fun". They just look so good. I have been wanting to add qr codes to the side of signs like that. Then you could have a link to a digital copy of the sign pattern (with housings included). I suppose you could put it behind a password or paywall to monopolize the proper repair... hey- someone's gotta pay for that server to host the files ;)