Over The Top Christmas Lights
2016 Behind the Scenes - Signs

One of the big additions this year will be two new LED full color signs. One is 38" x 24" and one is 76" x 25". Below you will find how the frames for the signs were made. Items used were 1 - 24' 11 guage 4" x 4" square steel pipe (cut into 4 pieces), 3 - 4" x 4" pressure treated posts for each sign, assorted bolts, washers, screws, connectors, and paint.

The 24' pipe was cut into 6' pieces and one side of the pipe was cut off leaving 28" from bottom. Four inches from cut side the two sides were cut and the front side was etched. The flap was then pounded inside to make a ledge inside. All the edges were smoothed off so as not to cause harm while working with the pipe. The ledge was then welded and the pipe was cleaned and painted. Holes were dug at the proper places so that 24" of the pipe would be underground. The 4 x 4's were cut on bottom at an angle so that they would tilt up into the steel pipe. Holes (1/2") were drilled through steel and wood and pins were pushed through. The post was tested to make sure they would tilt up then the upper holes were dilled the same way so the upper pins would lock post into place. A 4 x 4 was cut to fit across the top and bolted into place. The wood was painted and tested to make sure they would tilt up into the steel pipe.

Waterproof outlets was built and attached to the frames to plug the signs and router box into. The signs was bolted to the wood posts and tilted up, pinned, and locks were placed through holes that were drilled into pins. Signs were programmed and timmers set to start December 1st.

Click on a picture to enlarge it.


Pipe was cut into 6' pieces.

One side was cut off and smoothed off.

Four inches from cut side the two sides were cut and the front side was etched.

This side was then bent over into the pipe making a ledge inside. This was then welded to hold in place.

The pipe was cleaned and painted.

The 4 x 4s were cut at an angle so that they would tilt up into the steel pipe and holes were drilled in both wood and steel.

Holes were drilled at top of steel pipe and wood. Hole were dug so that 24" of pipe was in the ground.

Pins were made so locks would keep pins from sliding out. Frame was put up to test if all locked into place.

Everything tested many times to make sure it all worked correctly.

This is the larger sign put together.

This is the smaller sign put together.

These are the two signs working.

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