Vintage Neon Cowboy Hat

Materials:

1/8" aluminum sheet
tracing wheel
metal etch primer
1 Shot Sign Enamel:
- chrome yellow
- fire red
- black
brass 10/24 machine screws
neon tube supports
neon cable
9,000 V transformer solid state
neon - bent to fit pattern (custom made)
crackling agent - available at hobby stores
flat finish clear coat
chalk bag
plastic foam block
jigsaw
safety glasses
paintbrushes

1. Transfer the pounced (traced) image* to a 1/8-inch aluminum sheet using a tracing wheel (figure A) and chalk bag (figure B). *Draft desired hat pattern.

2. Place the aluminum sheet on a plastic foam block.

3. Cut out the hat image with a jigsaw (figure C).

4. File and sand the edges of the metal hat.

5. Prepare the aluminum sheet with metal etch primer.

6. Paint the aluminum sheet with 1 Shot Sign Enamel chrome yellow for the hat background (figure D).

• Transfer the designs for the hat details using the tracing wheel and chalk bag.
• Paint the hat details using fire red and black sign enamel (figure E).

7. Drill holes for the bolts that hold the transformer, tube supports, etc.

8. Paint a crackle finish on the vintage sign.

9. Attach neon (figure F), transformer and mounts.

10. Plug in the vintage neon cowboy hat and enjoy!

Website: www.roadhouserelics.com