And then when we finally got the green light they gave us three weeks to build and install the sign! Luckily they had given us a deposit and we had pre-ordered lots of the components, but we still had to work some long hours to make it all happen.
It's quite a process installing the neon tubing. Each piece has several tube supports that the glass has to be wired to, two PK housings to accept the ends, and rubber caps to keep the wiring dry. On the inside, wires must connect the back of each PK housing to the next one in line and eventually connect to the transformer. There were 152 connections in this sign and guess who had to crawl into the sign to make all those connection? Below you see me standing in the sign working on the easy part. It was way worse in the middle part of the sign.
When I was finally done making all those connections, and the Captain had installed all the glass, and our employees had installed the transformers, and done all the other little things to finish the sign, we turned it on and all the tubes lit up perfectly. So we left it running all night long. On Monday we rolled it into the trailer in preparation for Tuesday's install. And on Tuesday morning everything went smoothly and the sign was bolted onto the wall around 4pm. Whew!