Aluminum Gauge - 2' letters

[martyy]

Was looking to do a 2-layer name sign with individual letters being around 2ft tall. I have only cut mild steel and would likely use 16ga for something like this and maybe even use 18ga as the top layer. The sign will be outside and I was thinking this might be a good opportunity to try some aluminum to reduce any rusting. This will be powder coated. Not having touched a sheet of aluminum, not sure what gauge(s) to use. It needs to be sturdy enough that a marble size hail wont demolished it as we get hail yearly. Soliciting thoughts on gauge thickness from those that cut aluminum. Thanks

[plasmanewbie]

I used to do a lot of sign letters from aluminum and had really good luck with 14g. This will be thinner than 14g steel at approx. 065" thick.

[martyy]

I used to do a lot of sign letters from aluminum and had really good luck with 14g. This will be thinner than 14g steel at approx. 065" thick.

These will just be flat letters layered together. I had seen in an old post you have mentioned 3-4mm minimum, so was glad to see you chime in. Was thinking 1/8" might be overkill but I dont have anywhere close to put a piece in hand.

[adbuch]

Was looking to do a 2-layer name sign with individual letters being around 2ft tall. I have only cut mild steel and would likely use 16ga for something like this and maybe even use 18ga as the top layer. The sign will be outside and I was thinking this might be a good opportunity to try some aluminum to reduce any rusting. This will be powder coated. Not having touched a sheet of aluminum, not sure what gauge(s) to use. It needs to be sturdy enough that a marble size hail wont demolished it as we get hail yearly. Soliciting thoughts on gauge thickness from those that cut aluminum. Thanks

Are the individual letters around 2ft tall, or is that the overall size of your sign?
David

[martyy]

The individual letters will be just under 2ft with the back piece right at 2ft leaving an offset exposed.

[plasmanewbie]

The individual letters will be just under 2ft with the back piece right at 2ft leaving an offset exposed.

The 14g I used was more for indoor signage and letters that were smaller than your 2ft letters. The thicker material would be better for what your describing in my opinion. Interested to see what you come up with