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I made this sign from some scrap pieces of foam I had lying around. You can cut your boards to any size you want. Just make sure the box you build is large enough for your rope light to fit in to and there is adequate ventilation.
I used 1 inch foam for the front and back panels, then used some 2 inch foam pieces that were 3 inches wide and used these for the sides and bottom of my sign to create a box. I glued and clamped these pieces together and left them to dry for 3 days. I left the top of the box open, because that was the desired effect I wanted.
Next I printed out my letters on a printer and then spray glued them on to the foam box. After the letters had dried I took my Dremel and carved out my letters a 1/2 inch deep, making sure I did not cut right through the foam.
I then took a sand block and sanded my carved sign down, and vacuumed it since I find the foam dust particles stick to everything.
I painted my sign using Behr's Sandwash Paint. I did not paint the inside of the letters as I wanted the letters to glow through.
After deciding where my sign was going to plug in, I drilled a hole in the back of the sign, big enough for my rope light to be pushed through.
Lighting: I used a 3 foot extra bright light rope from Home Depot ( I believe it was about $4.00CDN). I plugged it in and wholla, an OHC sign!
Next year I will do one for the cemetary.
