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Montana Lettering Inc, Manufacturing & Distribuor since 2000
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Authorized Dealer for Gemini Sign Products
Cast Aluminum and Cast Bronze Letters & Numbers are the pinnacle of sign letter engineering. Manufactured in 40+ different styles, many with lowercase and sizes up to 18”, these letters present a sense of success and permanence wherever they are displayed.

 

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About Cast Aluminum and Cast Bronze sign letters from Gemini Sign Products.

A picture of a cast aluminum letter
Cast Metal letters are hand finished, lead free and surprisingly inexpensive. Made in all electric, pollution free furnaces, these heavy metal letters feature greater depths than can be found in any of the cut metal letters we make, and because they are castings, they use less metal and that translates to price per letter.

When considering a cast letter against a flat cut letter, consider the depth and price of cast when compared to a similar depth in cut metal. 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 cast aluminum letters carry a manufacturer\s lifetime warrantee and come in a variety of finishes and colors.

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 how to flush mount cast metal letters
FLUSH STUD MOUNT: Use this when mounting your letters flush to a flat surface. Whether it be drywall, brick, concrete, cinder block or wood, this is the most popular mount. Stud length for exterior use should be 2 inches in the wall. For drywall use, 1 inch is sufficient. Standard will be the factory choice based on the letter size.

Picture of jamnut mounts
PROJECTED JAM NUT: If you are mounting to an uneven surface, perhaps lap siding, metal corrugated building or rock, this mount allows adjustability. Essentially, the stud (threaded rod) get 2 nuts wound on to them and can be tightened against each other at a desired distance down the stud. By doing this the studs will only go into the wall up to where they are stopped by the nuts. This allows adjustability on all points of the studs. The image at left shows 3 possible configurations when mounting to a wall, a metal corrugated building or a flat metal plate or wall.

Picture of projected spacer mounts

PROJECTED SPACER : A spacer is an aluminum tube of various selectable size which slips over the stud providing a standoff from the wall surface. This is a uniform distance so if you wanted your letter to stand away from the wall surface by 1 inch then that is the spacer length you should select. The stud length should also be selected so that with a 1 inch standoff and 2 inches of stud in the wall surface, you will need a 3 inch stud. The further you stand the letter away, the more stud you should have in the wall to counteract the weight of the letter.

Picture of bottom stud mounts
BOTTOM STUD : (or top or both!) gives you tapped holes in the edge of the letters for mounting in a vertical configuration. Couple of things to consider here. Letters have to be at least 3/8" thick to drill the holes and the letters have a minimum height of 4" -BUT- that minimum is font AND letter dependent since many fonts will not have wide enough strokes to allow the drilling and tapping without it coming all the way out the other side(consider an "O" for instance). Normally when we do round letters we cut the bottom off flat with the rest of the flat bottom letters before we drill and tap it which makes the stroke thinner still. Ok, so point made, either big bold fat letters or bigger letters like 6-8" minimum. Same applies to top drilled letters.

Secondly, if you are considering using these outside on any kind of roof or overhang, you must tie them back either to a framework or by using aluminum or steel bars angled from the top back of each letter, down to the roof or ledge. Why? 2 reasons, wind load and the city inspector. Not sure which is worse but in either case all letters 8" or more must by code have tie backs when used outside.

This kind or installation is best left to professionals and please make sure you get this permitted before you attempt it. God forbid those letters come down in a strong wind and hit someone or damage property, you will be in deep trouble.

We do not have tie backs but you can make them from aluminum pipe and hammer over each end to make them flat.

Picture of how to mount cast metal letters on a bottom rail
BOTTOM RAIL: This is an addition to the mount above except we supply a U-Channel rail to attach the letters to. Maximum length of rail is 8ft and not available for letters greater than 24" or less than 4". Again, as per the information above for the bottom stud mount, 4" is minimum and not available for every font or even every letter shape. (see above)

Also, again the same as above, if you are considering using these outside on any kind of roof or overhang, you must tie them back either to a framework or by using aluminum or steel bars angled from the top back of each letter, down to the roof or ledge. Why? 2 reasons, wind load and the city inspector. Not sure which is worse but in either case all letters 8" or more must by code have tie backs when used outside.

This kind or installation is best left to professionals and please make sure you get this permitted before you attempt it. God forbid those letters come down in a strong wind and hit someone or damage property, you will be in deep trouble.

We do not have tie backs but you can make them from aluminum pipe and hammer over each end to make them flat.

Picture of how to mount cast metal letters on double rails
DOUBLE RAIL: Mostly used for installation on metal corrugated buildings. It does detract from the look of the sign and is considered old school. In today\'s world a metal conduit raceway from home depot would look better to mount your letters too and they come ready finished. That being said we offer the double rail mount in maximum 8ft lengths and the rails are pre drilled to accept the letters ordered with screws that go through the rail into the letters. Assembly is required. Another way to mount to corrugated buildings is to use the stud mount with spacer standoffs. Again if you cannot get behind the metal to attach nuts and bolts due to insulation then you can glue the studs in with epoxy. Time consuming but doable.
Metal Finishes
Image of the standard metal finishes Painted Colors
Image of the standard paint colors
CUSTOM FONTS
Custom fonts and shapes are available. We can also do custom sizes and depths but it is more expensive to order custom because we have to make molds for them. If you need a custom font please email or call.
INSTALLATION TIPS and VIDEO\'S
Video\'s Courtesy of Gemini Inc.
Please note these video\'s 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 warrenty 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.