There are two different ways to deal with curved letters during a DIY marquee letter project. I will be showing you both ways. The first up is to use metal flashing.
Firstly I want to start off by saying: be careful with the flashing, otherwise you are going to cut yourself with it. It is thin and the cuts are similar to paper cuts. Not fun but not life threatening either, just remember to clean them out and bandage yourself up if they do happen.
For this method I measured out roughly how of the flashing I would need. To do this I used a tape measure around the entire outside edge of the letter. Then gave myself a couple inches to play with and cut the flashing with my tin snips.
To make this easier I measured out each “side” of the letter and pre folded the flashing accordingly.
Once the flashing was pre folded I just tacked on the flashing to the edge of the letter. (I found it was easiest to use a ruler to measure where the tack should go into the side of the letter.)
Easy peasy and then my letter was done and ready for lights!
This method was definitely a much quicker way to create the marquee letter than the balsa wood is. It took me about 20 minutes from start to the finished letter.
Tip: To help keep the flashing secure add glue (E6000 is my all-purpose glue of choice) between the flashing and the letter edge.