How to Make a Backlit Display Box Sign

Lightboxes illuminate signs to draw attention to them.

A backlight display box is generally used to illuminate things placed on top of it. One common usage is to see pictures or the negatives of pictures. Backlight displays can also be used as a sign. The backlighting draws attention to the sign, increasing the chance of more people reading it. Though this type of display can be ordered from a professional, one can be made at home as well. You do need some proficiency in woodwork and basic wiring in order to accomplish the task.

Things You'll Need

• 1 6-foot 1-by-4 wooden board
• 1 3/4-inch plywood board 11.5-by-21.5
• 2 18-inch under board light fixtures with screws
• 1 heavy duty cord switch
• 1 extension cord, 18 gauge
• 1 white or opaque acrylic sheet, 11.5-by-21.5
• 1 1/2-inch drywall screw
• 9/64 and 7/64 drill bits
• 1 1/8-inch flat wood bit
• Circular saw
• Phillips screw driver
• Staple gun
• 1/2-inch staples
• Drill motor
• Countersink
• Acrylic paint
• Stencils (optional)

Instructions

1. Cut the 1-by-4 board down to two 20-inch boards and two 11.5-inch boards.

2. Place the 11.5 inch boards on the ends of the 20-inch boards then use two drywall screws to secure them at the joints. This will form an open box with no top or bottom.

3. Place the open box on top of the 3/4-inch plywood board to form the bottom of the box. Secure with drywall screws at each joint.

4. Drill a hole on one side of the board to fit the extension cord through. It should be 1 1/8 inches to fit the cord.

5. Remove and discard the plastic diffusers from each of the lamps. Remove the light tubes from each and set them aside.

6. Place the two lamps inside the box, making sure that the area where the light tubes will be is centered in the box and that they won't be touching each other.

7. Replace the tubes onto the lamps and turn them on to test.

8. Wire the heavy duty cord switch onto the cord, then staple the wires carefully to the plywood using the staple gun.

9. Lay the acrylic sheet down on your work surface. Measure out and mark a line that is 3/8 inch from the end of the sheet on all four sides. This will form a box within the sheet.

10. Drill a hole at each of the intersecting corners that you marked on the acrylic sheet. There will be four in total. Use the 9/64 inch drill bit for this. Anything bigger will rip at the sheet.

11. Drill two more holes equally spaced on each of the long sides of the board. Drill a hole between the two holes on each of the short sides of the sheet. This will make for a total of 10 equally spaced holes on the sheet.

12. Place the acrylic sheet on top of the box. Use the 7/64-inch to drill the 10 screws through the holes on the sheet and into the wood below.

13. Paint or stencil the letters or art for your sign directly onto the acrylic sheet. Alternately, you can simply tape or glue a preprinted sign over the sheet. Turn on the lamps to illuminate the sign.

Tips & Warnings

• If you can't find an acrylic sheet that is the exact size, get a larger one and cut it down to size.

• When using sharp tools like a circular saw, always use safety equipment and take precautions so that you do not hurt yourself. A circular saw can cause deep cuts and even amputation of fingers in severe cases.

References

• Carl McMillan: How to Build a Light Table
• Studio Lighting: Homemade Light Box for Product Photography