Making a Banner
Here are the steps in making a light, durable, waterproof, and relatively inexpensive banner (about 1/3 cost of vinyl banner made by printing business, reusable, and about half the weight). I didn't start taking photos early enough in the process to show each step.
Goal: Two 16 x 2.5 foot banners that say, "WE'RE ALL IN THE SAME BOAT, HEALTH CARE FOR ALL OREGON" in red and blue HCAO colors on white background. We used them in the Corvallis Christmas parade on Nov. 24, following an 18' tug boat being pulled by a trailer.
1. Light, durable, water repellent materials. The Rain Shed lady helped me chose white Flag Oxford, 5 yards for the banner and blue and red rip-stop, 2.5 yards, for the letters.
2. Stapler, long (12" arm).
3. Scissors (sewing scissors), good quality.
4. Computer, paper, and printer to make templates for 6" letters.
5. Cardboard, 6-8 feet x 2.5 feet to staple material to for initial stability of template placing.
6. Knives. Sharp round pizza-cutter blade works pretty well for longer straight cutting. Craft straight or curved blade can make initial penetration of fabrics then proceed with scissors.
7. Staple remover.
8. Light-weight joinable tent poles or equivalent.
1. Cut the 5 yards of Flag Oxford to intended size of banner (in my case 2 strips of 16 x 2.5 feet)
2. Print out the letter templates.
3. Staple rip-stop colored material to cardboard length-wise down the middle to stabilize rip-stop before placing letter templates. This is a time when you need the long stapler. Put down two layers of rip-stop if making two sets of signs. If so place both layers face-up because there is a slight difference in shade and texture front vs back.
4. Staple each 8" x 11" template sheet (inside and outside the letter itself) to the rip-stop material (but not to the cardboard). Stapling inside and outside the letter is necessary to keep the material from shifting as you cut.
5. Cut along straight margins of letter templates with knife or knives. Cardboard protects floor or table where you are working.
6. Pull rip-stop away from its mid-cardboard stapled attachment.
7. Finish cutting out letters in the rip-stop with scissors along the letter margins.
8. Separate newly minted rip-stop letters from the paper templates. Position horizontal center of message down 2.5" from top to allow for a support loop.
9. Place rip-stop letters on the Flag Oxford banners
10. Fold the top 5" of banner and staple every 6 " to form a loop for support poles to carry banner.
11. Staple letters to the banner.
12. May need to place weights (small plain kitchen magnets work) at bottom of banner to keep it from flapping too much in windy conditions.13. Insert support poles, join halves and tape together.
Assembly of game wheel.
1. Bike wheel of any size that rotates smoothly.
2. PVC 1" pipe about 6 feet in length.
3. Table saw or hack saw with fine teeth.
4. Flat piece of metal about 1/2" x 3" x 12" to use as brace.
5. Thin stiff piece of metal about 2.5" wide by 1/16" thick by 30" long to be used as pointer.
6. Electric drill to make 1/8" holes in PVC and metal brace.
7. 3-way 90 degree PVC joint for connecting legs at apex (1).
8. 45 degree PVC joint (2).
9. 90 degree PVC joint (3).
10. Frisbee as face plate.
11. 1/8" bolts long enough to fit through brace and PVC pipes (2). Nuts for bolts (2).
12. "Good question" flash cards.
13. Red or blue paint in spray cans.
1. Size the PVC legs to be long enough to hold wheel up and away from rubbing on the table or floor.
2. Cut the PVC legs and 4" connecting PVC pipes (at top of legs) to length. Wheel is tipped back so center of gravity will keep wheel from tipping forward.
3. Cut the metal brace to match the span between the legs.
4. Cut the point-shape on one end of the 30" piece of metal and drill or cut a hole near the center of the piece big enough for the axle tip to fit through. Bend the top 4" of the metal so the pointer points down in front of the spokes.
5. Drill central hole in brace so axle tip will fit into it.
6. Drill 1/8" holes in PVC to attach brace.
7. Spray paint all parts except wheel.
8. Bolt brace to PVC pipes.
9. Fit all the PVC pipes together10. Drill hole in center of frisbee big enough for axle tip.
11. Put tip of axle through brace and pointer metal and secure with axle nut.
12. Print sign for frisbee and laminate with clear laminating plastic (sometimes used on shelves).
13. Place frisbee on other axle tip and tighten axle nut.
14. Attach flash cards to spokes with bobbi pins.