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Montana Lettering Inc, Manufacturing & Distribuor since 2000
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Authorized Dealer for Gemini Sign Products


Anatomy of an aluminum channel letter for LED
Factory Installed L.E.D. modules included! Large Aluminum Sign Letters.


Anatomy of an aluminum channel letter for LED
Factory Installed L.E.D. modules included! Large Aluminum Sign Letters.


Halo Lighted channel sign letters
The look of our fabricated precision aluminum channel letters matches perfectly with the subtle and dramatic halo lighting effect produced by our reverse channel LED-lit letters. The lightweight solution for backlit channel letters 16” and up to 120” tall, these dramatic backlit aluminum channel letters are impossible to ignore yet won’t overwhelm your home or your shop floor. Our aluminum reverse channel letters feature a durable .090” (2.3mm) face gauge with .063” gauge returns, and offer a choice of polycarbonate backs with integrated LEDs to provide the lighting effect you desire. To provide outstanding light consistency and brightness, the interior of the cans are painted white. Halo Lit fabricated, produced with a removable can to allow for servicing of LEDs - or optional detachable studs to create a 1-1/2” stand-off, and allow easy removal of letters from the wall.
If you do not intend to light this product go here for cheaper options
 Step 1: Enter Letters, Numbers
Line 1
 Step 2 Size
 Step 3: Depth
 Step 4: Style/Font
 Step 5: Color/Finish
Displays your letters in the chosen font
 Step 6: Mounting Hardware
Line 1

Product comes with stud mounting hardware for the optimal 1.5" wall standoff. A fullsize Drilling pattern is provided.

 Step 6: Optional LED Package
 $0.00  |  0


  • LED Lit Pricing includes: Fabricated Stainless Steel letters - insides of cans painted white, Lexan backs for Halo lighting. UL Listed with Sign Section labels, lead wires/cables and power supplies* Standard leads are three wire, 36” long cables. Optional longer leads or individual wires available for these large lighted letters. Systems are 12VDC, Class 2 with 60 watt power supplies, max. 5 amps each. Wiring diagrams and instructions are provided with the LED lit sets for these aluminum channel letters. UL label location - optional location, per customer request.

    IMPORTANT: Letters are drilled and tapped for stud mounts. Typical 1½” stand-off to create a halo effect. Best halo is on a matte, light colored mounting surface

image of LED modules

  • Not Included: Electrical field wire, connectors, raceways, enclosures, hardware. All field wiring shall be 14 awg, stranded wire. Limitations on MINIMUM stroke widths Limitations on MAXIMUM stroke widths Mounting Options: Standard Halo Lit cans are produced with a removable can mount. Faces and Cans can be removed by loosening screws in the returns. Optional detachable studs can be ordered on request at extra cost which allows the entire letter with back to remove from wall and no visible return screws.
  • If you choose to install LEDs yourself, we recommend the following: • Order letters designed to be LED lit. • Always match your face colors with the LED colors. • Use only Low Voltage, High Quality, Low-profile LED systems in any plastic letter • Investigate the manufacturer to establish their stability in the market. Most legitimate manufacturers have an established warranty period and sell their systems through sign supply distributors. • Although LED systems designed for non-signage applications may be cheaper, they create problems at installation. For the greatest flexibility, consistency, and longevity, select a system designed with signs in mind.

Aligns the display output(below) either left, right or center justified. This image is passed along in your order. Alignment requires 2 or more lines of text. TIP: You can also indent text by using spaces before and after the text to move the line text to the left or right.

Sets a background to the preview so that you can judge the text color against a background color. Backgrounds are not provided in the order. All letters come as individual letters or numbers. We do not make the sign, we help you to make your sign.

This product is size and font dependent. Even our smallest size in some serif and narrow fonts may not be able to be fabricated and lit. While we want to offer as many choices as possible you need to be aware that the bigger the opening in the back of the letter is, the more likely it is to be producd in that size or style.

To install LED in the backs of these letters and produce a good halo effect we need to have at least 1" of depth. The smaller the letter size is the harder it becomes to fabricate and populate with LED for a good effect. The larger the letter size the more depth options will become available but keep in mind that more depth adds more cost.

This product is size and font dependent. Small sizes, usually under 12 inches in standard block styles may not be able to be fabricated and lit. While we want to offer as many choices as possible you need to be aware that the bigger the opening in the back of the letter is, the more likely it is to be producd in that size or style. When choosing 6" to 12" letters please us big blocky fonts, non serif(sans serif) and no scripts.

Type in the letters, numbers and punctuation, exactly as you want it to read when you make your sign. For multiple line signs, there are 3 other lines that will become available. What you type is what you will get. If lower case letters typed and the size is too small or lower case is not available in the chosen font, those letters will automatically convert to upper case and should convert back again when you change the height or size to something that has availability. What you type here will display in the preview area to the left along with correct real world dimensions. All letters are sent to you as individual letters and numbers, not as a ready made sign.

If you only want a series of numbers or numbers and letters for doors, then type them all in on line 1. Separate with a space but do not add comma's There is no need to add one number for each line.

If you want larger leading capitals in a phrase then you have to add the larger caps on a separate line.

This product is made from Stainless Steel and has several finish options available. For coastal areas you should choose Alloy 316 over Alloy 304. Gold, Copper, Bronze and Black metal finishes have a Titanium coating and are premium priced. The PAINTED tab gives you a choice of standard painted finishes to choose from or if you need a spacific painted color matched to Pantone, Sherwin Williams or PPG paints then we can do that for $20.00 per color matching fee. To have this option please provide the pantone or SW matching number in the comments box at checkout and we will add the extra charge and send you a confirmation.

A single powerpack can handle several letters at a time but since the amount of LED modules required to light a letter will vary depending on the size and shape of the letters ordered, it is not known how many powerpacks a given installation will require. Since the cost of the powerpacks is PER-ORDER rather than per letter, it is cheaper to order more than one letter at a time. Image of powerpack

This product is made for halo lighting. Unlike non-lighted letters found on the metal letters menu, this product has a light diffusing back plate made of Lexan with mounting hardware provided for an optimal 1.5" standoff. The interior of the letters are painted white and the LED modules (if ordered) are affixed to the back plate facing into the letter where the light is then diffused by the white interior and reflected back against the wall. Every letter is tested for even light output to match other letters in the order and the entire package carries a 5 year manufacturer warranty. You can also opt to provide your own LED modules