Replacement Acrylic Face for a Channel Letter, Cut to Shape

A cracked or faded face makes a whole sign look tired, but the rest of the letter is often fine. The stainless or metal return, the LEDs and the power supply can keep working; only the face needs to change. We cut a new translucent acrylic face to the exact shape of your letter so you can put the sign back to the way it looked.

Each face is built to order. To quote it, we need:

• A photo of the sign and a close-up of the damaged letter.
• The letter height.
• A rubbing or paper pattern of the old face, or the original artwork file if you still have it.

The pattern is the most important part. Tape a sheet of paper over the face and rub along the edge with a pencil or crayon, or take the old face out and trace around it. Mark which side faces out and which way is up.

Faces come in white or colored acrylic. If your fire marshal asks for a flame-retardant face, we can cut it in flame-retardant polycarbonate instead; standard acrylic is not flame-retardant.

These faces fit letters with a trim cap, the plastic edge that holds the face to the return. The trim cap is replaced with the face, so the new letter gets a clean new edge too. If your letters are trimless or have a different face system, send photos first and we tell you what fits.

While the face is off, check the LED modules inside. If some are dead or the light looks uneven, it is the cheapest moment to replace them, and our LED modules for channel letters come in the common whites and red.

Installation is not included. On a letter you can reach safely, a handy person can swap the face with the power off; for letters high on a building, a sign company with a lift is the safer choice.

Decide first whether only the face is the problem. If the letter lights evenly and only the face is cracked, faded or stained, a new face is the fix. If parts of the letter are dark, plan new LED modules at the same time.

For the color, white faces give the most light and the most even look. A colored face matches a brand color but lets less light through. If your old face had a vinyl film on white acrylic, tell us, because it changes what we cut.

Then make the pattern carefully, since the new face is cut to it. Send the photos, the letter height and the pattern or artwork, and say whether the sign is indoor or outdoor and whether the fire marshal has asked for flame-retardant material.