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Montana Lettering Inc, Manufacturing & Distribuor since 2000
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Authorized Dealer for Gemini Sign Products
Created by hand from pre finished sheets of Stainless Steel, these letters have an open back that can be populated with LED Modules
to provide halo lighting effects. Also available with an acrylic face for front lighted signs.

While this video is not using Fabricated letters, installing LED modules is essentially the same. You do not have to buy the letters with LED already in them. It may be considerably cheaper for you to buy your own modules and use this video to show you how to install them.


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About Fabricated Channel Letters made with Stainless Steel and fabricated by Gemini Sign Products.

Collage of stainless steel fabricated channel letters
In a world where nearly everything is produced en-masse on production lines in China, our Stainless Steel channel letters are HAND MADE in the United States by craftsmen sitting for hours on end at their workbench, carefully crafting each letter with hand tools to produce outstanding quality that will last a lifetime. This is not just a slogan, we back it up with a lifetime warranty on every letter produced. If you choose the LED installed option, we provide top quality GE Tetra LED modules and components that carry a 4 year limited warranty. Simply put, we produce a top quality product, hand made in the USA at a reasonable price.

Fabricated channel letters require the craftsmen to weld seams inside the letter(can) where the edge meets the face. The smaller and deeper the letter is, the harder it is for the craftsman to do their work and the more the letter will cost. Simple economics. The rule of thumb is that the smallest part of the letters stroke width(multiplied by 2), determines the depth the letter can have. Therefore, if a letter is 4" tall and the smallest part of the letters stroke is 1/2" across(x 2), the maximum letter depth is 1". On serif and script fonts the width of the smallest part of a letter at any given height can still be very small indeed which means that the minimum height of the letter must increase dramatically. It should be noted that the LED installed option does require a 1" minimum letter depth which in effect doubles the minimum starting size that can be accomplished.

When used outside, occasional maintenance is always a good idea. Once a year, check all the mounting hardware to make sure it is firmly attached to the building. Make repairs as necessary and should you need to replace a failed letter, just send us an email with a picture of the failure, your name and address and your original order number and we will have the factory make a new one and ship it to you at no charge. Cleaning the letters should also be done as needed. A simple soapy water solution is all that is required to bring your letters, numbers and logos back to their original sparkling condition.
Picture of how to stud mount fabricated channel letters
The most widely used mounting method for fabricated channel letters is the stud mount. The image on the right depicts the strap mount where a strap of steel is welded across the letter stroke and a threaded boss holds a removable stud (threaded rod) which in turn gets glued into holes in your wall with silicon, epoxy or other types of adhesive. For LED halo lighting, the recommended stand off from the wall surface is 1.5" so you will likely receive 3" studs with your order. The option on the left is known as the side mount. We have decided not to allow you to specify which one should be used since they both have applications that would be better for the factory to decide based on the letter size, its depth, whether or not its getting a back and of what type, and even the font and the finish have to be taken into account.

Picture of how to stud mount fabricated channel letters
Back covers come in 2 materials, Lexan or Steel. The image above at left shows a lexan back plate attached to a removable front(known as a can). The screw on top of the can allows the front cover to be removed leaving the back cover firmly attached to the wall. The stud screws through the back cover into its threaded boss. This type of mount and cover configuration is used for the LED ready and LED installed options. The Image above and to the right depicts a NON-Removable can with a steel back. The hole accepts the stud and the screw above it holds the back to the front. Once installed on the wall, the cans are not removable without taking the whole letter down.

Picture of how to stud mount fabricated channel letters

Lexan back cover on a NON-Removable can. The hole accepts the stud and the screw above it holds the back to the front. Once installed on the wall, the cans are not removable without taking the whole letter down. Finally, the engineered stud at above right is used for free standing letters such as on a roof or a ledge. This option is not available on all fonts and we don't even have a price for it but we know that it is expensive. This would be a special order item and the price will be given us on an as requested basis.
Titanium coated swatches showing colors and grain
When it comes to fonts, configuring fabricated channel letters is one of the hardest products we have. There are so many things to take into consideration that it is frankly amazing that we have been able to offer it online at all. Just writing the script for this product took over a week of work and even now there will be things that simply cannot be done and times where we have to write you and say that we have to change the size or make it fatter, or less deep, or that we cannot even produce it.

If you need a font not listed you will have to request it along with the size and depth required, whether it will be populated with LED or a simple plain can. We then have to request a quote from the manufacturer and it can be quite complicated.
Serif font style differences between script and sans serif font styles
Videos Courtesy of Gemini Inc.
Please note these videos cover many types of letters that may not be applicable to the products on this page.
The correct place to start is where you intend to mount your letters. Visualize how much space your sign will take up, then measure the space. If you are in a city and this is an outdoor sign it is wise to find out if you will need a permit from the city. Some cities have strict rules on signage, how much space they will allow in terms of square feet, the type of sign, how it will be mounted and what it is made of. These are the first steps. The next step is the difficulty factor. Most people do not have man lifting equipment to work at high levels. Ladders may not be safe considering the work to be done. You should determine if the savings you will get by buying the letters and self installing is worth the cost of renting a lift and the hazards involved. If in doubt, stop, get your local yellow pages out and call a professional sign company.

When you buy your letters, numbers and logos directly from a manufacturer or distributor, it is assumed that you will be installing the products yourself. In this regard you are acting as your own sign company with all the benefits and pitfalls that might entail. Essentially, the average DIY handy person can easily install their own sign as long as it is at ground level. Our mounting patterns take all the guesswork out of it but it is essential that you get all your ducks in a row before you decide to buy the letters. While on the subject of sign companies it should be said that many sign companies do not want to install letters unless they have supplied them. It is a warranty issue for them and it is also a money issue since they make money on the purchase of sign letters for your project. If you intend to have a sign company install, do yourself a favor and let them do the entire job.