Montana Lettering Inc, Manufacturing & Distribuor since 2000

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Authorized Dealer for Gemini Sign Products
Created from CAB, a cotton fiber based plastic, vacuum formed plastic letters, numbers and logos provide greater depth than conventional cut plastic letters at a very low cost. Chose from 82 styles, many with lowercase and sizes up to 48”, these letters come in a wide array of standard colors and can additionally be painted any color you need.


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Mounting Hardware

no mount option

Not recommended for the non-professional. This product is hollow in the back and without some form of mount in it will be impossible to mount. Running screws through the face will void the lifetime warranty. Sign Professionals Only!

flange mount option

A flange mount leaves a flat edge of material around the perimeter of the letter where you can run screws through. This kind of mount is often used on corrugated metal buildings and the flange and mounting screws are painted the color of the building to hide the flange.

pad mount option

Plastic pads extending about 1/8" beyond the back of letter allow you to use silicon on the pads and glue to a flat surface. Installed with use of a pounce pattern or spacing guide. Not recommended for outdoor installations or uneven surfaces.

stud mount option

This is the default stud mount. This option will have blocks glued in the backs of the letters that accept threaded rods(studs). Drill corresponding holes in the mounting surface using the drilling pattern available at extra cost, then fill the holes and coat the studs with silicon and push the letter to the wall. A drill mounting pattern is required.

combo mount option

The combo or combination mount differs from the combination all mount in that it only has stud THROUGH pads on the tops of the letters and standard PAD mounts on the bottoms. This mount is useful where you want to drill as few holes as possible and still have mounting rods(studs) in the wall. Installed by drilling holes for the stud through pad and adhering non stud pads directly to mounting surface. A drill mounting pattern is required.

combination all mount option

The combination all mount is stud through pad on all points. This gives you adjustability on every stud and is useful for irregular surfaces such as corrugated metal buildings, lap siding, stone walls or anywhere you want a standoff from the wall that is adjustable during installation. A drill mounting pattern is required

wire mount option

Has "L" shaped wire loops that protrude at the back side of the letter for your wood screws. Wires can have a stand off or fit flush to wall. Specify standoff if required. Minimum 9" height required

bracket mount option

The bracket is similar to the wire mount except the "L" shape is made of plastic. Flush mount only. Minimum 9" height required

Mounting Patterns

drilling pattern for stud mounted letters

Full size Drilling patterns are tracing of letters done by hand at the factory. The letters, with studs screwed into the back or into blocks, are then punched through the paper to show the exact location of the studs. Once taped onto a wall, the hole locations are then drilled and filled with adhesive for any installation using a threaded stud. $3.25 per letter.

pattern for pad and tape mounted letters

A guide for plain, pad or double face tape mounted letters. The letters in a specific copy are spelled out and properly spaced on a long pattern table or computer generated. A narrow (approximately 2") piece of paper contains small hash marks or plotted lower portions of the letters. This guide is then secured to the wall with tape by the installer and provides a visual guide for installing letters. $10 - ANY QUANTITY.

Chrome Finishes

polished chrome formed plastic letters

Formed letters and logos with an opaque chrome finish are suitable for interior or exterior applications. Available in single pieces up to 45 inches by 68 inches, the finish is durable and provides the ultimate chrome finish in a deep dimensional letter. These pieces are perfect for automotive businesses, nightclubs and trendy up-scale clients looking to freshen up their brand. Image is everything and these pieces have it. Adds 250% to price

satin chrome formed plastic letters

Made with the same UV-stable plastic as the Polished Chrome finish, Brushed Chrome provides a slightly different look that many businesses find appealing. Adds 300% to price

Standard Face Finishes

Also available in 46 standard painted colors or your custom Pantone, Sherwin Williams or other color

sample of a vacuum formed plastic letter color #2025 black
sample of a vacuum formed plastic letter color #4310 dove grey
sample of a vacuum formed plastic letter color #5687 White
sample of a vacuum formed plastic letter color #2718 Ivory
sample of a vacuum formed plastic letter color #4660 Dessert Sand
sample of a vacuum formed plastic letter color #20000 Yellow
sample of a vacuum formed plastic letter color #2540 Mango
sample of a vacuum formed plastic letter color #2119 Orange

2025 Black

4310 Dove Grey

5687 White

2718 Ivory

4660 Desert Sand

2000 Yellow

2540 Mango

2119 Orange

sample of a vacuum formed plastic letter color #2662 Red Orange
sample of a vacuum formed plastic letter color #2793 Red
sample of a vacuum formed plastic letter color #1875 Brick Red
sample of a vacuum formed plastic letter color #2240 Maroon
sample of a vacuum formed plastic letter color #2287 Purple
sample of a vacuum formed plastic letter color #2767 Midnight Blue
sample of a vacuum formed plastic letter color #2050 Dark Blue
sample of a vacuum formed plastic letter color #2860 Medium Blue

2662 Red Orange

2793 Red

1875 Brick Red

2240 Maroon

2287 Purple

2767 Midnight Blue

2050 Dark Blue

2860 Medium Blue

sample of a vacuum formed plastic letter color #3000 Blue
sample of a vacuum formed plastic letter color #2648 Light Blue
sample of a vacuum formed plastic letter color #3210 Teal Blue
sample of a vacuum formed plastic letter color #2108 Light Green
sample of a vacuum formed plastic letter color #2030 Dark Green
sample of a vacuum formed plastic letter color #2162 Hunter Green
sample of a vacuum formed plastic letter color #2418 Brown
sample of a vacuum formed plastic letter color #6371 Yellow Gold

3000 Blue

2648 Light Blue

3210 Teal Blue

2108 Light Green

2030 Dark Green

2162 Hunter Green

2418 Brown

6371 Yellow Gold

sample of a vacuum formed plastic letter color #2756 Metallic Gold
sample of a vacuum formed plastic letter color #6366 Copper
sample of a vacuum formed plastic letter color #3120 Medium Bronze
sample of a vacuum formed plastic letter color #3130 Duranodic Bronze
sample of a vacuum formed plastic letter color #8886 Metallic Silver

2756 Metallic Gold

6366 Copper

3120 Medium Bronze

3130 Duranodic Bronze

8886 Metallic Silver

About Vacuum Formed Plastic Letters, Numbers and Logos from Gemini Sign Products.

A picture of a vacuum formed plastic letter D
Vacuum formed plastic letters are the correct choice for outside signage where low cost and high visibility with lots of depth are the desired requirements. These letters come in a variety of standard colors and 90+ styles with sizes up to 48", many with lowercase letters.

Depending on letter or number size, the depths of Vacuum Formed Plastic Letters can go from 3/8" all the way to 2". These letters are the right choice for any environment whether it be the arid South Western States, the humid South Eastern States or the Northern States where temperatures can drop to sub zero. These all weather plastic letters carry a manufacturer\s lifetime warrantee against fading, cracking and chipping.

Prices are very reasonable too since the manufacturing process uses sheets of colored cellulose acetate butyrate (CAB), a cotton based fiber plastic that is totally "green" and free of any petroleum base. This makes the product extremely resilient and does not harden and crack like normal plastics do when left outside.

Like anything left permanently 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 a plain no mount letter
NO MOUNTS: This option should be avoided if possible since all molded letters are hollow in the back and cannot easily be mounted. All sizes and styles of fonts have some kind of hardware mount except the 2" Architectural Bevel Face Font so if you choose that font at 2" the only options are to either fill the back with expanding foam or with silicon. Never screw through the face as you will most likely crack the plastic and will void the warranty.

Picture of a letter with a pad mount
PAD MOUNTS: Couple of issues with pad mounts. They can be messy to install since they employ some form of glue spread on the perforated pad. When sticking to your sign they will also need to be secured with masking tape for a while. That is easy on a dry flat surface like drywall where masking tape will stick to, but try it on stucco or brick and good luck! Second is letter alignment because the patterns available are not really designed for this type of mount. Last, due to the diameter of the pads you may see them beyond the letter when viewing straight on and especially so from the side.

Picture of a letter with stud mounting hardware

Picture of how to measure for a stud for brick mount

Picture of a letter showing how to mount it away from the wall
STUD MOUNT: Studs, also known as pins, are threaded rods that screw into threaded holes in the backs of the letters. On material less than 3/8" thick, we use a mounting block glued to the back of the letter to accept the threaded stud. This also gives a letter stand-off of about 1/4 to 1/2". The stud is an aluminum threaded rod and can be ordered in various lengths starting at 1".

Mounting is as simple as drilling holes into a wall, drywall, brick masonry, wood, stucco etc; , filling the holes with silicon caulk, liquid nails, epoxy or even mortar, and then pushing one into the other. For this operation a mounting pattern is highly recommended or you will not know where to drill the holes. Studs can also be passed through a substrate to allow for nuts and washers to be attached to the back.

If you are mounting to a real brick wall and do not want to drill into the bricks, select the stud for brick option and we can drill the threaded holes in rows along the backs of the letters that are equal distance apart based on the measurement you choose from the Stud for Brick" option.

And finally, don't overdo the standoff option. Just because you can do something does not mean you should and many novice installers really go overboard with this thinking it gives the letters definition and shadow. In reality it just reveals all that non finished hardware behind the letters and makes it easy for people to steal. Heck, they don't even need to bring a pry bar! Mounting pattern is required.

Picture of a letter with combination type mounting hardware
COMBINATION MOUNT : For uneven use on lap siding, slopes or even just to avoid having to drill so many holes, the combination mount is so called because it is a combination of the pad mount and the stud mount. At the tops of each letter, an adjustable stud through pad allows for adjustability away from the surface while the bottom of the letter has fixed pads. Drill holes only for the top studs which anchor to the wall and then the bottoms get your favorite adhesive and surface mount to the wall. Mounting pattern is required.

Picture of a letter with combination all mounting hardware
COMBINATION ALL : This mount provides stud through pads on each location. The pads screw up and down the studs and can be configured for stand-off, lap siding, ribbed metal buildings and other uneven surfaces. Mounting is as for the stud mount and the combination mount. Mounting pattern is required.

Picture of a letter with an adjustable pad mounting hardware
ADJUSTABLE PADS : Same basic mount as the pad mount except it does provide a small amount of adjustment on each pad to allow for uneven or lapped surfaces.

Picture of a letter with a flange for screw  mounting
FLANGE MOUNT : This is not so much a hardware mount as it is a way to secure letters to walls or ribbed metal or lighting boxes. Essentially the same as the no mount option, the flange mount provides a 1/4" band of material around the letter profile so that you can attach with screws or glue direct to a surface. If the letters are big enough, greater than 12" or so, this type of mount makes it easy to mount to ribbed metal buildings since the letter forms will in most cases span the ridges and valleys of the wall, allowing you to run self tapping screws into the ridges around the letter perimeter. This type of mount is also good for light boxes where you can glue the flange direct to the clear acrylic panels of a light box. In this case be sure to order a lightable color if you want the letters to glow.

Picture of a letter with outside wire loop mounting hardware
WIRE MOUNT : Yet another surface mount, this mount has some standoff capabilities by ordering wires that have a longer shank. Basically, this mount provides several wire loops for use with screws for attaching directly to a wall. Not the easiest mount to use but good for some situations.

Picture of a letter with outside bracket mounting hardware
BRACKET MOUNT : Similar to the wire mount but with no adjustability, this mount uses plastic "L" brackets that can be attached by running screws through and into a wall.
Standard Plastic Colors
Standard pigmented colors Painted Plastic Colors
Standard paint colors
satin chrome finish
polished chrome finish
Check out the Chrome video on this page under the "Chrome Finish" tab
In vacuum formed plastic we can offer custom fonts and logos or shapes but the price is higher than it is if you were to purchase one of the 80+ styles we currently have molds for. For custom molding we have to make molds and that is not only an extra expense but also requires more time to produce.
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 involved, do yourself a favor and let them do the entire job.