We finally got to use these at our wedding!! We ADORE how they turned out! It was 100% worth the time and effort.
Oh. My. Gosh. We FINALLY finished this project!! Read through to see how we did it, and scroll to the bottom to see the updated budget breakdown and materials list.
If you need to get caught up on the DIY Marquee Letter saga, check out part 1, part 2, and part 3. Here’s how it started: before we even bought our house, we went to a wedding expo and spotted these marquee letters. We instantly fell in L.O.V.E. with them and had to figure out how to make our own!
Finally, we decided it was time
give the people what they wanted finish ‘er up. And that meant doing the hardest part: adding the metal flashing to the sides. We bought four rolls of 6-inch aluminum flashing because we wanted our letters to have metal siding (there are some tutorials online using poster board for the sides but we wanted something a little more sturdy). We couldn’t find any tutorials for making wood and metal letters so we decided to wing it.
(Before we get into all the pictures, a quick side note: we worked on this project on and off over several months so don’t be surprised if our outfits, location, time of day, and Evan’s haircut-necessity-level change from picture to picture.)
We started with the L because it was the easiest and because we are just OCD enough that the thought of doing the letters out of order bothered us. The first step when adding the flashing is to unroll your metal and sit the letter on it.
Choose where you want the start and the end of your metal to meet (for the L, we chose the bottom of it), then make your first bend in the metal. We used the help of a putty knife and a hammer to make our bends.
Draw a line on the metal where you want your bend to be, place the sharp end of a putty knife (or similar object) on that line, and hammer the handle of the putty knife so that the sharp end is pounded into the metal. This works best if you’re working on carpet or a rug instead of a hard table top or hard flooring. You need some give underneath the metal to allow the putty knife to push into it.
You’ll notice in the photo above we have a few bends in the metal already. Once you make your first bend, you’ll need to measure along your letter to find out where on the metal roll to make the next bend. So for the L, we did it like this:
We started the edge of the metal where it says “Start” above and measured how far that point was to the lower right hand corner of the L (where “A” meets “B”). On the metal, we measured that same length from the edge and made a 90 degree bend using the putty knife and hammer technique. We did that all around the L. The angle marks above our rainbow-esque metal flashing in the guide above indicate what direction the angle is bent at.
It’s pretty easy to do this for each letter as you go, but if you chose a complex looking font it could get tricky. Therefore, we highly recommend a sans-serif font!
For some letters, like the L, it was pretty easy for just one person to do the measurements and bends.
But other letters were two-person jobs, like the E. I never thought about how many angles a capital E has until we had to bend sharp metal around every one of them! For the E, I needed to hold the flashing up while Evan measured and bent so that it didn’t fall onto itself. And sorry about the PJ’s. Although it took us months to finish this project, extra time could not be spared to get properly dressed.
Once you have all your angles made, you’ll see the shape of the letter start to form and you can wrap the metal around your letter! Ahhhh!! Exciting!! Just don’t forget to cut off the extra metal (see it to the left of the L in the image below) with some sturdy clippers. We liked to leave a couple inches of overlap when we cut it.
We did not take a picture of the O at this stage of completion because it required a slightly different method. Since the metal did not have any bends or corners to hang onto, it wouldn’t stay put. So I had to pretty much wrap myself around the letter while Evan hammered nails in to anchor it. This is actually the only picture we have of this stage of the O because it was all hands on deck for this one.
Which brings us to our next step: attaching the metal.
First we made guide lines on the metal so that we could center it against the edge of our plywood. Since our plywood was 1/2-inch thick and our metal flashing was 6-inches wide, we marked dots that were 2-3/4 inches from each side (so that there was a 1/2-inch space between them going down the center of the metal).
Then we connected our dots and used those as our guide. These marks were made on the side of the metal that would be attached to the wood.
In hindsight, it would have been easier to do this before bending the metal. Oh hindsight!
On the other side of the metal (the side facing outside), we marked dots along the center of the metal (3 inches from the edge) so that we knew where to nail. We made a dot every inch or so, but you could do more or less if you wanted.
Since we had our plywood and nail guides, we wrapped the metal around the letters, aligning the plywood with our 1/2 inch space on the inside of the metal. Evan hammered in a nail or two while I held it in place to keep it from shifting.
We used short 1/2-inch finishing nails to do the job. We started out originally using longer nails, but a few times we didn’t hammer them in straight enough and their ends poked through the wood (ooops!). When that happens it’s kind of a pain to carefully pull them out without causing more damage.
But the 1/2-inch nails were harder to hammer because holding such a tiny nail was difficult. So we used our longer nails to hammer little pilot holes through the metal and just barely into the wood, and then hammered our shorter nails into the pilot holes. It was WAY easier. Also, we still (carefully) used the longer nails at the corners because we felt like that they might be a better anchor.
So after Evan hammered in a couple nails to keep the metal from shifting, together we’d go down each side of the letter and create pilot holes, and then add our 1/2-inch nails. Lots and lots of nails.
The V and the E needed a little extra help because there were areas in each that we couldn’t nail due to lack of space for the hammer. On the V, we couldn’t get the hammer passed a certain point in the “dip” of the V. So we decided to nail as far as we could and then use epoxy.
That didn’t work too well because it was hard to hold the metal against the wood long enough for it to set. We didn’t have a big clamp, so we tried to wedge enough random tools in there to hold the metal down in place. I’ll pause while you laugh.
Yeah. That didn’t work. So we went to Home Depot, got some Gorilla Glue, and picked up a big clamp. And then taped the crap out of the whole thing because we really really didn’t want another glue fail.
The Gorilla Glue worked! But it squished out the sides (womp womp) and we had to cut the excess off with a razor blade, which was annoying. When we did the other side of the V, we made sure to apply as little glue as possible so that we didn’t have the same problem again.
Even though the Gorilla Glue worked, there were a lot of places on the E that we couldn’t use nails and we didn’t want to deal with all the gluing and clamping again.
So for the parts of the metal that went in between the “legs” of the E, we bent them so that the sides were curving toward the wood of the E (like the colored pieces in the image below) and then hammered a few nails in between each bent piece of metal to hold things in place (along with nails around the perimeter of the letter too of course). Since the curved metal naturally wanted to press against the wood, we didn’t need any glue there.
After the metal was firmly attached to all our letters, it was time to screw in our lights! We used two packs of these outdoor lights. Depending on the size of your letters and the closeness of the holes you drilled, you may need more or less.
We had to screw in the lights in a way that made sense with the flow of the letters. Meaning for the L, we started at the bottom (so that we didn’t have to have a cord running from the floor to the top of a letter) and we added lights going toward the top. But we skipped every other light so that when we reached the top of the L we could make our way back to the bottom, filling in the lights we had skipped on the way up.
On the O, we went straight across from the L to the base of the O and looped around clockwise until we got to the part of the O that was closest to the top of the V, filling in every light up to that point. Then as we continued the O (past the point closest to the top of the V) we just filled in every other light again until we reached out O starting point, where we then backtracked and filled in the holes we missed. Similar to the method on the L.
Basically, any time you know you’re going to have to backtrack, start skipping every other hole so that when you make your way back you have holes to fill in.
We wired the lights this way because we didn’t want to have long stretches (like from the outlet to the top of the L or the base of the O to the top of the V) where there were lights that weren’t being used. Because that meant wasted lights, and we really didn’t want to buy a third pack. Hope the graphic above helps make sense of it! If not, it will make more sense when you get to this point and start playing with it.
I am happy to say, after much measuring, hammering, cutting, hammering, gluing, and hammering… we are FINALLY done!
So of course we had to take a million pictures…
We love the look of the metal and wood. On this zoomed in picture of the O you can really see how snugly everything fits together.
We L.O.V.E. them sooooooooo much! Can’t wait to have these at our wedding, and we are super excited that they’ll have a spot in our home for us to enjoy forever :)
Finally, here’s the budget breakdown. This is all rounded, but it’s pretty accurate:
(2) 2ft x 4ft pieces of pre-sanded plywood – $30
(4) rolls of 6 inch metal (similar to this but longer and therefore pricier) – $24
(1) 8-oz can of Minwax stain in Dark Walnut – $5
(2) packs of clear globe lights – $38
Nails, hammers, clamps, saw, brushes, etc – already owned/needed to have anyway
TOTAL = $97
Not bad for four very sturdy 2-ft tall letters that we love!