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I mark both ends of the slot and drill a small hole in each end.  There's a skinny blade for a zona saw that you can then drop in the hole and connect them together.

You could also just drill a series of 1/16" holes along the length of the slot and then file it out. Once the sign goes on, you wont notice what you've done to the roof, but its important that you get it straight enough that the sign material slides through without flexing or bending. Those EL elements are a bit fragile at the connection tab.

Last edited by Boilermaker1

Thanks for all of the replies!  I did try the exacto knife route, but my hands are not steady enough to make straight lines on smooth plastic.  I opted for the Dremel tool, but I used a cut off disc/wheel that I had previously used to cut my track, this produced a nice slot for the connection point on the sign.  Now I will warn you that it burns/melts the plastic and it smells, but if you can get past that, it does produce a good result.

I will post some pictures of the layout and I will include one of the sign.

Darren

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OGR Publishing, Inc., 1310 Eastside Centre Ct, Suite 6, Mountain Home, AR 72653
330-757-3020

www.ogaugerr.com
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