Materials:

• Birch plywood
• 1.5 inch corner trim
• 1/4 inch square stock
  
• Piece of plexi-glass
• Vinyl Letter stickers
• Black spray paint (for plastic)
  
• pull-chain switch
• remote control outlet switch (meant for lamps, provides remote control options for the light)
  
• 12v DC Power adapter (I got mine on eBay.  Just search for 12v DC power adapter.)
• Red Cold Cathode 12V computer lights

       Available from computer stores.  These are meant for computer cases but will run on any 12V DC source.  They produce no heat and last forever.  I get mine on eBay from all_city.

• DC power jack (matches plug on power adapter, I got mine from Radio Shack.  Check this list for the right size http://en.wikipedia.org/wiki/Coaxial_power_connector#RadioShack_Adaptaplug_conversion_matrix)
  
• Screws
• Wax paper
  

Build box from plywood.  Add in recessed lip to support plastic front supported with screws from the outside.




 



Attach lights to inside, install switch and power plug.






Stick the letters to the plastic front.  Spray paint the entire piece black.  Let this dry for at least 24 hours.  CAREFULLY peel off letters revealing the sign.



Cover back of sign with wax paper so the insides of the light aren't visible. 



Drill holes to secure the front to the box. By using screws this will be removable for maintenance.




Cut corner trim on 45* angle to cover seams.  Attach the trim on the side with screws so it can be removed for maintenance. 


  Use metal brackets to hang the sign.