The concave background was routed from 4" thick Precision Board. It was a deep cutting file, coming within a half inch of the bottom.
We mocked up the sign onto the welded steel frame and did a little adjusting as necessary to make it look good visually. The biggest change was to drop the oval a little from our original design.
Once we were happy we marked reference points and then disassembled so we could spread the glue.
We then lifted the pieces into place.
We then double checked the alignment before clamping and screwing the pieces together. The lettering is slid into position in the steel structure. This way we can remove it for painting and building the base plus we can make further adjustments to the width as we go.