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FLEXCASEFOR SINGLE OR DOUBLE SIDEDFLEXIBLE FACE SIGNS

The FlexCase Family

FlexCase StandardRecommended for large canopysigns, fascia signs andwall - mounted signs.

FlexCase

FlexCase Light DutyRecommended for cost effectivecanopy signs and fascia signs up toapproximately 3000mm in height

The FlexCase Family

FlexCase Double SidedFor suspended, projected or post-mounted signs.May be manufactured in two widths: 305m and 372.5mm

Retro - FlexFor converting existingsign boxes to acceptflexible face.Also a slim solution fornon-illuminated flexibleface signs fixed directlyto wall.

FlexCase profiles are available anodised or powdercoat painted in a wide choice of coloursas well as in mill finish. The system can be supplied in bar length, in kits or as fully manufacturedsigns, complete with lamps, electrics and face.

A weekly delivery service is operated to most areas of the U.K. mainland.

For further information please contact:

Universal Aluminium Systems.Universal House.Pennywell Road,Bristol.BS5 0ER

United Kingdom

Tel: +44 (0) 117 955 9091 I Fax: +44 (0) 800 378 144mail to: signs@universal-aluminium.co.ukweb: www.universal-aluminium.co.uk

Introduction and SpecificationThe hallmarks of the FlexCase range of sign box andflexible face tensioning systems are:

Fast fabricationEasy InstallationSimple and accurate face tensioningTrouble-free maintenance with nodisturbance to the flexible face tensioning

The great inherent strength and rigidity of theFlexCase box allows the sign maker virtually unlimiteddesign freedom to produce high quality signs ofseamless and frameless appearance in a wide varietyof sizes.

Standard - for manufacturing single sided signs of anysize or shape.

Light Duty - for smaller single - sided canopy andfascia signs up to approximately 3000mm in depth.

Double sided - for pole mounted or suspended signs.

Retro-Flex - for converting existing sign boxes toaccept a flexible face and for manufacturing slim profilewall or fascia mounted non - illuminated flexible facedsigns.

Corners, whether internal or external, present noproblems with FlexCase. Two alternative methods ofcorner construction are possible with the standard system- full illuminated or with cover plates - making the systemideal for multi - sided canopy installations such as onpetrol stations. FlexCase can be seen on many suchprojects throughout the UK., Europe, the USA., the MiddleEast, the Far East and Latin America.

FlexCase profiles may be finished to the followingspecifications:

- anodized to BS 1615 or BS 3987 in Silver.- stoved powder organic coating to BS 6496 in white and a range of RAL colours (to special order).- in mill finish.

Finish

For further information on the FlexCase system please contact us on Tel: +44 (0) 117 955 9091 or Fax: (0) 800 378 144 (FREE)

mail-to: web: signs@universal-aluminium.co.uk www.universal-aluminium.co.uk

The FlexCase system is available to signalers in bar length profile-please ask for details and prices

FlexCaseIntroduction and Specification

FlexCaseStandard System

FlexCaseStandard System

Fast fabrication; easy installation; simple and accurate face tensioning;trouble-free maintenance - these are the hallmarks of FlexCase.

The only sign box system designed to fulfill all the unique demands offlexible face materials, FlexCase has been designed in close collaborationwith sign makers, lighting specialists and substrate manufacturers. Thesystem has been tested and approved by 3M for use with Panaflex facematerials.

Key features of the FlexCase system are:

Maximum frame strengh achieved with minimumnumbers of components to save on fabrication time andinventory cost.

Full perimeter concealed face tensioning system withaccurate adjustment for wrinkle-free faces every time,achieved without the use of fiddly clips.

Hinged access flaps to all sides of the sign box to allowfast and easy maintenance without disturbing the face -no hinging or de-tensioning required!

Fewer lighting tubes required in most installations - savingon manufacturing and running costs.

Aluminium Sign Box Systemfor single sided flexible face signs

220mm

RodRDO 701

Tension BarUCL 263

OuterJoining Sleeve

UCV 328

Double WidthSupportUCL 247

SupportUCL 259

220mm

HingeSectionUCL 265

Brackets assembliesto be riveted here

InnerJoining Sleeve

UCV 329

Support to beriveted here

Back Panelto be

riveted here

HingeCorner Angle

UCL 253cs

Component

Cover PlateHinge Section

Vinyl Bar

Support

Tension BarRod

Corner Angle

Back Panel

(UCL 261)(UCL 265)

(UCL 264)

(UCL 259)

(UCL 263)(RDO 701)

(UCL 178)

Cutting formula

Mitre cut to overall dimensions ofsign

Mitre cut at 7mm less thancover plate and hinge section usingjig blocks supplied

Cut at 59mm less than theheight of the box

Cut at 80mm less thancover plate and hinge sectionNOTE: For illuminated corners withadjusters cut vertical rod andtension bar at 24mm lessthan cover plate and hingemeasurement

Cut at 27mm or use UCL 253cs

Cut at 100mm less thanfinished box on both length anddepth

FlexCaseStandard System - Profiles and Accessories

Cover PlateUCL 261

Vinyl BarUCL 264

Bracket / PullerBolt / Clamp Plate

UCL 260cs

(Available doublewidth - UCL 250cs forvertical supports andUCL 466cs for side

supports

Vinyl Barto be riveted

here

Standard System

Box FabricationLay hinge section and cover plates on bench as shown below:

UCL 261

UCL 265

UCL 253CS

Drill corner angles and rivet into both ends of short hinge section.Insert cover plates in channels in all hinge sections. Slide cornerangles of short sections into ends of long hinge sections. Pull upcover plates all round and tape corners. Pull mitres tight, drilland rivet corner angles in long side.

Supports (UCL 259) are required at each end of the box and atapproximately 750mm centres.Bracket / bolt / puller assemblies (UCL 260cs) should be fitted tothe ends of each support using a jig*, the threaded clamp platesand bolts supplied. On the two end supports, bracket / bolt /puller assemblies should also be attached at right angles to thevertical, one at each end and at 750mm centers. To fix thesebrackets to the end supports the fixing bolt should be secured inthe centre hole in the clamp plate.Note: On boxes over 2000mm deep, double supports (UCL 247)and puller assemblies (vertical UCL 250cs, side: UCL 466cs)should be used instead of single supports (except at each end ofeach section on multi-section signs).

*Jig made from a small off-cut of UCL 265 hinge section.

Vinyl Bar AssemblyOn short sections drill 5mm holes on die lines 4mm from cornerand countersink lightly. Secure corners with No. 8 x 30mmscrews driven into screw ports in adjoining vinyl bar. With box onbench face upwards, offer up vinyl bar frame and insert into topof box, making sure it fits fully onto the two legs on each bracketassembly.

Drill and rivet vinyl frame onto brackets front and back.Universal recommends that the front face of the vinyl bar ispainted white

PaintWhite

Back PanelBack panel should be recessed into body of hinge sectionextrusion then drilled and riveted at approximately 254mmcentres and through each support. Adhesive tape may be placedover panel / box joints to provide additional weather proofing.

Two joining sleeves are available for joining sections ofFlexCase vinyl bar.

Joining Box Sections

UCL 329

UCL 328

VinylBar Screw or rivet

here

Tubes should be set at 300mm centres which will give asaving in electrical equipment initially and considerablesavings in running cost.

Tube Layout

Cut and stitch vinyl face as described.Vinyl Face Assembly

P a r t i c u l a r l y u s e f u l f o r v e r y l o n g s i g nboxes built in several sections, the sleeves are simply cut tolengths of approximately 150mm and secured by rivets orscrews into the vinyl bar section.

The sleeves make accurate alignment of box sections easyto achieve.

The recommended spacing for tubes in most acrylic facesigns is 200mm so a cost comparison can easily be carriedout.On signs up to 1200mm wide, tubes should be sethorizontally to enable maintenance to be carried out viathe hinged cover plate.

On signs 1500mm wide and upwards tubes should be severtically for maintenance purposes.Signs up to 5500mm can be illuminated using vertical andhorizontal tubes complete with central “tombstone” twistand turn fittings.Care should be exercised when positioning gear trays andfused terminal blocks to ensure they are within reach forease of maintenance.In normal conditions when tubes are set horizontally, theyshould be overlapped to ensure even diffusion of light.This overlap should be a maximum of 150mm.

Slide rods into loops in the vinyl then slide the tension baralong it with the grooved side facing inwards on all foursides. Make sure the puller blocks on all bracket assemblies are about 20mm from the front of the boltsand locate ends of bolts into channels in the vinyl bar.Place the face over the box and hook the puller blocks intothe grooves in the tension bar making sure all are engagedbefore taking up the tension.

Take up the slack at both ends of the face then tension theface diagonally as shown in the diagram. Do Not OverTighten The Ends As DISTORTION May Result. Followthe sequence A-A B-B etc. as shown below.

Tensioning Procedure

Ideally tensioning is a two-man operation.D F

A

E

B

C G

G CH

H F D

B

E

A

To fix cover plates drill 3.5mm holes at about 32mm fromeach corner and countersink to take a No. 8 3/4” screw.Repeat at approximately 700mm centres around theperimeter of the box.

Cover Plates

FlexCase

Corner Assemblies - Fully Illuminated

UCL 121 CornerPuller

Assembly

UCL 326 CornerBar

InternalCorner

Castings

ExternalCorner

Mouldings

UCL 424 UCL 425(For illuminated

corners)

External CornersHinge sections and supports are fabricated in the same way aspreviously described.

Vinyl bar sections should be square cut at the ends which areto form the corner to a length 120mm more than theback edge dimension of the box.

Two pieces of corner bar (UCL 326) are cut to 16mm less thanthe overall box heightIf the corner is to have face tensioning, slide pullerassemblies on to rear of corner bars and position atapproximately 75mm from each end of the bars. Drill andsecure with 10mm No. 8 self-tapping screws. On deeper signsadditional puller assemblies may be positioned at the centreof the puller bar. Attach a corner casting UCL 424 to the topand base of each corner bar by drilling and fixing with 10mmNo. 8 self-tapping countersunk screws.

Place corner bar assemblies face to face and tape together.Drill a 6.5mm clearance hole through corner bars at thecentre point. Tap ONE hole to accept a 30mm M8 hex, headset bolt and open out the other hole to 9mm clearance. Thisinstruction applies to wrap round or face tensioned corners.Take each corner bar and insert the lugs on each cornercasting into the ends of the vinyl bars, drill holes through thevinyl bar into each lug and rivet.If the corner is to have face tensioning, two pieces oftension bar (UCL 263) and rod (RDO 701) should be cut to130mm less than the overall box height and fitted to the vinylface as previously described.

Face installation is made easier by means of a corner spreader(UCL 414) which should be fitted to the rear legs of the vinylbar as show in the diagram below.After tensioning the face, the corner bars should be pulled uptight by means of the centre bolt which should be pushedthrough the pre-drilled and tapped holes in the corner barsand holes in the face material.On wrap round corners bolt corner bars together beforefitting the face.

Plan View

ExternalCorner

Corner spreader

UCL 414

Hole dr i l led intop leg of vinylbar, 5mm clearanceto accept bolt ofcorner spreader

Puller

Vinyl bar

UCL 264

Corner BarCastings fit intovinyl bar and aredrilled and riveted.

Corner bars securedto top and bottomcastings.

Corner bars aresecured with abolt driven intopre-tapped hole.

PullerVinyl face

Remove section ofhinge here to allowcover plates to slidein and out.

Cover PlatesTo make external corner manufacture easier, cover platesshould be cut into manageable sections at each corner. Toenable the cover plate sections to be easily fitted and removed,chamfer about 25mm of metal from the corner of the hingesection (see diagram)

Internal CornersVinyl bar section should be square cut at the ends which are toform the corner to a length 221mm less than the back edgedimension of the box.

Corner bars (UCL 326) are cut and fitted in the same way as forexternal corners (using corner castings UCL 425 and pullerassemblies). The above instructions should be followed,

InternalCorner

Plan View

Puller

Corner Bar

Puller

Corner bars aresecured with abolt driven intopre-tapped hole.

Castings fit intovinyl bar and are

drilled and riveted.

FlexCase

Corner Assemblies with Cover Plates

Universal recommends the use of this type of corner forboxes over 1500mm high

Cut corner assemblies (UCL 272) (two for each corner) at7mm less than overall box height dimension. Drill two 5mmclearance holes on die lines at each end (see Diagram).Hole A at 6mm from edge and hole B at 41mm from edge.Drill 9mm holes on die lines on rear faces of both cornerassemblies at 60mm from top and bottom edges. and atcentres not exceeding 600mm depending on the height ofthe box. Attach puller bolts, pullers and Nylok nuts into eachhole.

Drill 9mm holes on die lines on rear flanges of both cornerassemblies at 300mm centres.

Note: Outside corner - vinyl bar (UCL 264) is cut at141mm more than the dimension of the back edge ofthe box, mitred at 45°. Inside Corner - vinyl bar is cut at216mm less than the dimension of the back edge of the.box.

A recess 12mm deep should be cut or filed toaccommodate corner covers (see Diagram).Secure corner assemblies to vinyl bar using 1 1/4” No. 8screws located into screw ports in the vinyl bar.Hinge sections (UCL 265) are mitred at 45° and rivetedtogether using corner bracket UCL 252cs.Supports (UCL 259) and bracket assemblies should be fittedinto the hinge section as previously described and should bebutted together at the corner.Both corner assemblies/vinyl bars should be offered onto legsof maincase brackets and riveted as previously described.Finally, corner assemblies are bolted together at rear flange.Tension bar (UCL 263) and rod (Rd0701) are cut at 50mmless than overall box height and fitted to the vinyl face aspreviously described.

When the puller blocks are hooked into the grooves on thetension bar, the face can be tensioned using a box spanner.Corner cover plates (UCL 271 or 273) are drilled on die linesand secured with No. 8 screws.Note: Flanges on inside of hinged plates should beremoved where necessary to allow the plates to sit flatonto corner assembly.

Corner BracketUCL 272

Corner ChevronUCL 252cs

Drill 9mmholes here

Drill9mm holes

here

Radius CornerCover

UCL 273

Right AngleCorner Cover

UCL 271

recess 12mm deep

UCL 272

UCL 271 or 273

UCL 265

UCL 252cs

Hole A

Hole B

A

B

FlexCase

Standard System - Radius Corners

203mm radius corners are available to fit the standardFlexCase system.

Kits contain all parts required to fabricate four cornersand include:

- Hinge castings (for standard system only)- Vinyl bar castings- Puller assemblies- Cover plates

Corner HingeCasting

Corner VinylBar

Cover Plate

Tension Bar Casting

Flexible RodMaterial Cutting

Cover Plate (UCL 261)

Component

Hinge Section (UCL 265)Vinyl Bar (UCL 264)Tension Bar (UCL 263)Rod (RD 0701)

Support (UCL 259)

Back Panel

Cutting Formula

Square cut at 474mm less than overalldimensions of box*

Square cut at 408mm lessSquare cut at 412mm less than overall dimensionsof box.

Square cut at 60mm less than height.

Cut at 100mm less than size finished.

*Due ti slight variations inevitable in the cuttingand rolling of corner cover plates. Universalrecommends that cover plates are cut to suit ateach corner to ensure an accurate fit.

Lay hinge sections, corner Hinge and cover plates onbench as shown below.

Slide cover plates into all side hinge sections. Push tabof corner hinge casting FULLY into each end of shorthinge sections. Drill through hinge section and castingsand secure with rivets or self tapping screws.

Slide tabs of corner castings on short sections FULLYinto ends of long hinge sections, drill and secure aspreviously described.

Supports are required at 50mm from the end of eachhinge section and at approximately 750mm centres.

Supports, Brackets and Pullers

Bracket/bolt/puller assemblies (UCL 260cs) should befitted to the ends of each support using a jig and thethreaded clamp plates and bolts supplied. On the twoend supports, bracket/bolt/puller assemblies shouldalso be attached at right angles to the vertical, one ateach end and at 750mm centres. To fix these bracketsto the end supports the fixing bolt should be secured inthe centre hole in the clamp plate.

The side brackets should be fixed to 224mm long piecesof support section which should be butted at 90° to thevertical supports and secured with plates.

Note: On boxes over 2000mm deep, double supportsand puller assemblies should be used.

Place box on bench with face upwards. insert supportsand bracket assemblies into box, making sure that theends of the brackets go fully into the channels in thehinge sections. Turn box over and position supports ateach end and at 750mm centres. Drill a hole in thebottom right hand of each support where the die linescross. Secure with a rivet, Check each support and thebox for squareness then drill and rivet at the bottomleft hand of each support. Turn box over and drill andrivet through hinge section and tongue of each bracket.

Push legs of corner vinyl bar castings FULLY into eachend of both short sections of vinyl bar. Drill throughvinyl bar into both legs of each casting and secure withrivets or self tapping screws. Secure short sections ofvinyl bar to long sections in the same way, ensuringthat the castings are FULLY pushed into the bars.

Vinyl Bar Assembly

With the box on bench face upwards, offer up vinyl barframe and insert into top of box, making sure it fitsfully onto the two legs on each bracket assembly.

Drill and rivet vinyl frame onto brackets front and back.Universal recommend that te front face of the vinyl baris painted white. (Available painted white from Universal).

FlexCase

FlexCaseLight Duty

Aluminium Sign Box Systemfor single sided flexible face signsDue to the worldwide success of the FlexCase sign box and tensioningsystem this light duty version has been introduced to meet the demandsfor illuminated vandal-resistant vinyl faced canopies and fascia signsup to approximately 3000mm in depth.

Although incorporating all the unique features of the FlexCase system,FlexCase Light Duty offers considerable cost savings. The system is idealfor petrol station canopies as well as for long fascia signs on carshowrooms, shops, banks etc.

Installation and Tensioning of the vinyl face is fast and accurate. The fullperimeter, adjustable tensioning system ensures that graphics andlettering are accurately aligned and wrinkle-free.

Maintenance of lighting and electrics can be undertaken via the hingedaccess flaps provided all round the sign box without de-tensioning ordisturbing the face in any way.

External illuminated corners can be incorporated into canopy signs usingstandard components from the FlexCase system.

FlexCaseLight Duty

196mm

FlexCaseLight Duty System - Profiles and Accessories

FlexCase Light Duty enables single sided flexible face signs to be made cost effectively. The system isideal for canopy and fascia signs and can be manufactured in any length and up to approximately3000mm in height, providing that it is fixed securely at each end to prevent distortion.

Vertical supports (UCL 364) are required at each end of the box and at approximately 750mm centres.

The face is tensioned using threaded tensioners which are supplied fitted to bracket assemblies(UCL 464). Bracket assemblies are fitted to each vertical support. On the sides of the box, bracketsassemblies are required at each corner and at approximately 750mm intervals.

FlexCase Light Duty profiles are available anodized to BS 1615/3987 or powdercoat painted to BS 6496in white or a range of RAL/BS colours (to special order). Profiles are also available in mill finish.

Hinged Cover PlateUCL 363 Rod

RDO 701

Tension BarUCL 263

Vinyl BarUCL 360

Joining SleeveUCL 328

(Fits insideUCL 360)

Hinge SectionUCL 362

Bracket / PullerUCL 464

Used for joiningindividual sections

of long signs

Corner AngleUCL 465

SupportUCL 364fits here

Corner AngleUCL 465fits here

Vinyl Barsecured to

support here

Double SupportUCL 366Support

UCL 364

FlexCaseLight Duty System - Assembly Instructions

UCL 261

UCL 265

UCL 253CS

Material Cutting

Cover Plate (UCL 363)

Hinge Section (UCL 362)

Component

Tension Bar (UCL 263)

Rod (RD 0701)

Support (UCL 364)

Back Panel

Cutting Formula

Mitre cut to overall dimensions of sign

Cut at 80mm less than cover plate/hingesections

Cut at 39mm less than the overall height of thesign

Cut at 40mm less than overall dimensions offinished box on length and depth

Vinyl Bar (UCL 360) Mitre cut at 7mm less than cover plate/hingesection (using jig blocks)

Corner Angle (UCL 178) Cut at 17mm or use UCL 465 (pre-cut)

Box FabricationLay hinge sections and cover plates on bench as shown below.

Drill corner angles (UCL 465) and rivet into both ends ofshort hinge section. Insert cover plate in channels in all hingesections. Slide corner angles of short sections into ends oflong hinge sections. Pull up cover plates all round and tapecorners. Pull mitres tight, drill and rivet corner angles in longsides.

Supports (UCL 364) are required at each end of the box, andat approximately 750mm centres. Bracket/ bolt/pullerassemblies (UCL 464) should be fitted to the ends of eachsupport ensuring that the nib at the top edge of the bracketlocates over the ends of the supports.

On the two end supports, bracket/bolt/pullerassemblies should also be attached at right angles to thevertical, one at each end at 750mm centres.

Place box on bench with face upwards. Insert supports andbracket assemblies fully into the channels in the hingesections.

On short section drill 5mm holes on top die line 4mmfrom the corner and countersink lightly.

Vinyl Bar Assembly

With box on bench face upwards, locate sections ofvinyl bar onto the two legs on each bracket assembly.Secure vinyl bar sections at each corner using No. 8x 25mm screws driven into ports in adjoining vinyl bar.

Drill and rivet vinyl frame onto brackets front and back.

Back panel should be recessed into body of hingesection extrusion then drilled and riveted at approximately254mm centres and through each support. Adhesivetape may be placed over panel/box joints to provideadditional weather proofing.

Back Panel

A joining sleeve (UCL 328) is available for joiningsections of vinyl bar.

Joining Box Sections

Particularly useful for long sing boxes built in severalsections, the sleeve is simply cut to lengths ofapproximately 150mm and secured by rivets or screwsinto the vinyl bar sections

Tubing should be set at 300mm centres which will givea saving in electrical equipment initially and considerablesavings in running cost. The recommended spacing fortubes in most acrylic face sings is 200mm so a costcomparison can easily be carried out. Care should beexercised when positioning gear trays and fused terminalblocks to ensure they are within reach for ease ofmaintenance.

Vinyl Bar UCL 360

Joining Sleeve UCL 328

Tube Layout

In normal conditions, when tubes are set horizontally,they should be overlapped to ensure even diffusion oflight. This overlap should be a maximum of 150mm

Turn box over and move the supports into position at each endof the box and at 750mm centres. Drill a hole in the bottomright hand of each support and secure with a rivet. Check eachsupport and the box for squareness then drill and rivet at thebottom left hand of each support. Drill and rivet each supportat the top. Turn the box over and drill and rivet through hingesection into each bracket and support. FlexCase Light Duty can be manufactured with full

illuminated corners using the same method as theStandard system.

Illuminated Corners

FlexCaseLight Duty System - Assembly Instructions

Vinyl Face Preparation and InstallationCut vinyl to 250mm more than overall size of box. Fold to forma loop 38mm as shown below.

Slide rods into loops in the vinyl then slide the tension bar alongit with the grooved side facing inwards on all four sides. Makesure the puller blocks on all the bracket assemblies are about10mm from the front of the bolts and locate ends of bolts intochannels in the bracket.

Tensioning ProceduresTake up the slack at both ends of the face then tension the faced i a g o n a l l y a s s h o w n i n t h e d i a g r a m b e l o w.DO NOT OVER TIGHTEN THE ENDS AS DISTORTION MAYRESULT. Follow the sequence A-A, B-B etc as shown below.

D F

A

E

B

C G

G CH

H F D

B

E

A

Cover PlatesTo fix cover plates drill 3.5mm holes at about 32mm from eachcorner and countersink to take No. 8 screw. Repeat atapproximately 700mm centres around the perimeter of thebox.

Ideally tensioning is a two-man operation.

+ 125mm

Ove

rall B

ox

Heig

ht

38mm

Overall Box Length

125mm 125mm

+125mm 87mm

38mm

LoopStitched

Here

Kerf cutting profiles for shaped signsCircular or oval FlexCase signs can be manufactured bymeans of kerf cutting the vinyl bar, hinge and tension barprofiles before bending to shape around a template.

Universal recommends that saw cuts should be approximately50mm apart and that each cut should be tab welded aftershaping the profile.

For further information or technical assistance please contactUniversal.

FlexCaseDouble Sided

FlexCaseDouble Sided

Aluminium Sign Box Systemfor double sided flexible face signs

Fast fabrication; easy installation; simple and accurate face tensioning;trouble-free maintenance - these are the hallmarks of FlexCase.

The only sign box system designed to fulfill all the unique demands offlexible face materials, FlexCase has been designed in close collaborationwith sign makers, lighting specialists and substrate manufacturers. Thesystem has been tested and approved by 3M for use with Panaflex facematerials.

Key features of the FlexCase system are:

Maximum frame strengh achieved with minimumnumbers of components to save on fabrication time andinventory cost.

Full perimeter concealed face tensioning system withaccurate adjustment for wrinkle-free faces every time,achieved without the use of fiddly clips.

Hinged access flaps to all sides of the sign box to allowfast and easy maintenance without disturbing the face -no hinging or de-tensioning required!

Fewer lighting tubes required in most installations - savingon manufacturing and running costs.

FlexCase Double Sided utilizes most of the componentsfound in FlexCase Standard and is used for pole mountedor suspended signs.

Bracket ExtensionUCL 369

FlexCaseDouble Sided - Profiles and Accessories

RodRDO 701

Tension BarUCL 263

OuterJoining Sleeve

UCV 328

InnerJoining Sleeve

UCV 329

Bracket andDouble Puller

UCL 286cs

Large Cover PlateUCL 289

Small Cover PlateUCL 284

HingeCarrierUCL 290

Vinyl BarUCL 264

67.5mm

UCL 369

FlexCaseDouble Sided - Fabrication

305mm

372.5mm

UCL 369

The Double Sided FlexCase system can be used tomake signs of two alternative widths: 305mm or372.5mm.

When manufacturing the wider version, use thebracket extension (UCL 369) and two wide coverplates (UCL 289).

Make up both vinyl bar assemblies as per instructions givenfor standard system.

Material Cutting

Cover Plate (UCL 289 & 284)

Hinge Carrier (UCL 290)

Component

Tension Bar (UCL 263)

Rod (RD 0701)

Cutting Formula

Mitre cut to overall dimensions of sign

Cut at 80mm less than Cover Plates

Vinyl Bar (UCL 264) Mitre cut at 7mm less than cover plates(using jig blocks)

Box Fabrication

Lay one completed vinyl bar frame on the bench, facedownwards. Position main bracket/puller assemblies 80mmin from each corner and at approximately 750mm centresaround frame. Ensure brackets and frames are square thendrill and rivet on both sides.

Note: Ensure that raised “ear” on brackets slopesdownward

Slide both wide and narrow cover plates into hinge carriersections.

Raise wide cover plates on long sections and position hingecarriers onto raised “ears” on brackets. Repeat this operationon short sections. Pull all four sides up tight and tape thenarrow cover plates and hinge carrier at each corner.

Drill and rivet hinge carriers at the “ear” of each Bracket.Place second vinyl frame, face upwards no top of bracket/pullerassemblies then drill and rivet both sides. The sign is now readyto receive faces which should be fitted and tensioned in thesame way as the standard system

Double sided FlexCase signs can be suspended by means ofthreaded rods which should be fitted trough both the wide topcover plate and specially positioned extra main support sections.(The support sections should have pullers and bolts discardedfor this purpose).

Suspended Signs

The wide cover plate should be cut at each side of the rod sothat the remaining sections of cover plate can still be raisedfor maintenance and face tensioning.

Pole MountingTo fix centrally mounted 100mm pole to a double sidedFlexCase sign use a main support at each side of the pole atboth top and bottom of the sign. The pole should be attachedto the main supports by means of angle pieces screwed orwelded to both support and pole.

The top of the pole should be 50mm from the top edge of thesign so that the cover plates can still be raised along thecomplete top edge for maintenance and face tensioning.

At the base of the sign hinge sections and cover plates shouldbe cut at each side of the pole and butted up to it. Small fillerplates should be used to fill the two remaining spaces atfront and back of the pole.

Wall Mounted Sign

Cover plate sectionscut to size

Hinge carriercur each sideof supporttube

Support tubeweldedbrackets

Cover plate sectionscut to size to fitbetween supports

3” squaresupport tube

Pieces of cover platecut to size and usedto fill gaps. Fixedto small angles screwedto tube

Anglesfixed tosupporttube andbracket/pullerassemblies

FlexCaseDouble Sided - Radius Corners

Cover Plate (UCL 289 & 284)

Component Cutting Formula

Square cut at 463mm less than overalldimensions of box

Hinge Carrier (UCL 290)Vinyl Bar (UCL 264)Tension Bar (UCL 263)Rod (RD 0701)

Square cut at 405mm less than overalldimensions of box

Material Cutting

Make up both vinyl bar assemblies as instructions given forstandard system.

Lay one completed vinyl bar frame face downwards on thebench. Position main support/puller assemblies (UCL 286cs)at each end of all straight lengths of vinyl bar and atapproximately 750mm centres around the frame.

Note: Ensure that raised “ear” on supports slopesdownwards.

Ensure supports and frames are square then drill and riveton both sides.

Slide both wide and narrow cover plates into all hinge carriersections.

Raise wide cover plates on long sections and position hingecarriers onto raised “ears” on support extrusions. Repeatthis operation on short sections.

Drill and rivet hinge carriers to the “ear” of each support.Place second vinyl frame, face upwards on top of support-puller assemblies then drill and rivet both sides. The sign isnow ready to receive faces which should be fitted andtensioned in the same way as the standard system.

When the face is tensioned, the hinge and corner cover platesshould be drilled and fixed with screws as per instructionsgiven for standard system.

Cut and stitch vinyl as described earlier.

Vinyl Face Assembly

At each corner the vinyl must be cut into fingers using thetemplate supplied with corner kit.

Slide rods into the loops in the vinyl on all four sides thenslide on tension bars, ensuring that the grooved side facesinwards on all sides.

At each corner slide a flexible rod through the loops in thefingers of vinyl then slide on the tension castings.

Make sure the puller blocks on all bracket assemblies areabout 10mm from the front of the bolts and locate ends ofbolts into channels in the vinyl bar.

Place the face over the box and hook the puller blocks intothe grooves in the tension bar making sure all are engagedbefore taking up the tension.

Locate the ends of the bolts on each corner tension castinginto the holes in the vinyl bar casting.

Tension the face diagonally as described earlier. DO NOTOVER TIGHTEN as distortion may result.

To fix cover plates drill 3.5mm holes at about 32mm fromeach corner and countersink to take No. 8 screw. Repeat atapproximately 700mm centres around the perimeter of thebox.

Cover plates

Locate corner cover plates into the grooves in the cornerhinge castings then drill and fix in position with screws atfront and each end.

FlexCaseStandard and Double Sided - Radius Corners

+115mm 76mm

38mm

LoopStitched

Here

Standard and Double Sided Systems

NORMAL BOX

Cut vinyl to 230mm more than overall size of box. Foldapproximately 76mm to form loop 38mm.

Cut vinyl as follows

+ 115mm

Ove

rall B

ox

Heig

ht

38mm

Overall Box Length

115mm 115mm

Note: Vinyl should be stitched to form a loop on all foursides of the face.

Standard System - Fully Illuminated Corners

Length - Back dimension of box plus 440mmfor each corner and 115mm for each end

Note: Vinyl should be stitched to form a loop on all foursides of the face.

Depth - Overall box height plus 230mm

WRAP ROUND CORNERS

RIGHT ANGLE INTERNAL CORNER WITH FACE TENSIONERS

Cut vinyl as follows

Length - Back dimension of box plus 383mmfor each corner and 115mm for each end

Depth - Overall box height plus 230mm

Note: Vinyl should be stitched to form a loop on all foursides of the face.

Cut vinyl as follows

Length - Back dimension of box less 57mmfor each corner and plus 115mm for each end

Depth - Overall box height plus 230mm

Note: Vinyl should be stitched to form a loop on all foursides of the face.

115mm

Plan View

Back Edgeof Box

115mm

Face

Standard System: 220mm

Light Duty System: 196mm

RIGHT ANGLE INTERNAL CORNER WITH FACE TENSIONERS115mm

Plan View

Standard System: 220mm

Light Duty System: 196mm

Face

Plan View

Face

Standard System: 220mm

Light Duty System: 196mm

1

m63

m115mm

orner Spreader

CUC

414

L

FlexCaseStandard System - Corners with Cover Plates

Corner to Straight EndCut Vinyl as Follows:

Length - Overall box length plus 181mmDepth - Overall box height plus 230mm

Fold approximately 76mm to form a loop 38mm all round

Note: Vinyl should be stitched to form a loop on all foursides of the face.

Cut Vinyl as Follows:

Length - Overall box corner to corner measurementplus 152mm

Fold approximately 76mm to form a loop 38mm all round

COMPLETE WRAP AROUND SIGN

Depth - Overall box height plus 230mm

Note: Vinyl should be stitched to form a loop on all foursides of the face.

115mm

Ove

rall B

ox

Heig

ht

Overall LengthCorner to Corner 76

115mm

74mm

Elevation

7476mm

115mm

Ove

rall B

ox

Heig

ht

Overall Straight Edgeto Corner115mm 76

115mm

74mm

Elevation

Plan View

Overall Straight Edge to Corner

74mm

150m

m

74mm

74mm

150m

m150mm

Plan View

Overall Length Corner to Corner

FlexCaseRetroFlex

FlexCaseRetroFlex

Universal Retro-Flex offers the most cost effective and efficientmethod of converting existing sign boxes or canopy signs to acceptflexible face material.

Aluminium Sign Systemfor Converting ExistingSign Boxes to FlexibleFace

Adjustable full perimeter face tensioning for wrinkle-freefaces every time. This allow for extremely accurate alignmentof graphics - especially when close to the edges of the face.

Hinge system for fast and easy maintenance with no disturbanceto the face tensioning.

FlexCaseRetroFlex - Material Cutting and Profiles

Cover Plate (UCL 284)Hinge/Fixing

Plate (UCL 321)Hinge (UCL 320)

Component

Tension Bar (UCL 263)

Rod (RD 0701)

Cutting Formula

Mitre cut at 6mm more than outsidedimensions of existing sign box.*

Cut at 80mm less than cover platesdimensions.

Vinyl Bar (UCL 264) Mitre cut using jig blocks to 2mm less thanoutside dimensions of the existing sign box.*

Reinforcing Support SectionUniversal recommends the useof UCL 331 supports for signsover 1 metre in height.

Vertical Supports - cut at 20mm less thanheight of existing sign box.

Slide Supports - cut at 102mm long

Material Cutting

* Existing sign box should be carefully measured to ensure accurate fit of Retro - Flex box.

Cover PlateUCL 284

HingeUCL 320

Hinge/Fixing PlateUCL 321Hinge

UCL 327

TensionBar

UCL 263

RodRDO 701

ReinforcingSupportUCL 324

Heavy DutySupportUCL 331

“T” Plate

UCL 415

Puller KitUCL 412

Vinyl BarUCL 264

Vinyl BarAdapterUCL 295

This profile is used tomanufacture non-illuminatedflexible faced sign boxes forfixing directly to walls orfascias etc. It is used insteadof profiles UCL 320/

Fix to existing box withnuts, bolts and washersalong TOP of box

ExistingBox

Rivet hinge tosupports here

PullerAssembly

Reinforcingsupport

Hinge

ExistingBox

Secure with Self-Tapping screws

Vinyl BarAdapter

Vinyl Face

Vinyl Face

120mm

Reinforcingsupport

FlexCaseRetroFlex - Fabrication

Fabricate vinyl bar assembly as described earlier and placeface down on bench. Place pieces of vinyl bar adapter on tothe rear legs of the vinyl bar, one at each end and atapproximately 750mm centres around the frame.

Box Fabrication

Drill through adaptor and vinyl bar at back and front atboth ends and secure with rivets.

Drill an 8mm hole through each vertical support section45mm from each end. Drill through one end only of eachside support.

Slide the head of a 45mm bolt (supplied with puller andbracket assembly) into the channel of each vinyl bar adaptor.

Make up the two end support assemblies with a verticalsupport and side supports joined with “T” plates drilled andriveted or screwed in position as shown below.

Position all support sections on bolts, make square and securewith washers and nuts.

Back View of Retro-Flex Box

Note: When using heavy duty support (UCL 331) the rearlegs of the support have to be removed for a distanceof 25mm at each end.

Fit a puller and bracket assembly on each adaptor sectionby sliding head of short bolt into channel, securing withwasher and nut.

Place one long and one short section of hinge over the endsof the support sections.

ENSURE THAT DIE LINE ON LEG OF HINGE FACESTOWARDS YOU.

ENSURE THAT DIE LINE ON LEG OF HINGE FACESTOWARDS YOU.

Rivet hinge tosupports here

Rivet

Ensure corner mitresare tight then drill twoholes through the hingeleg into each support sectionand secure with rivets.

Slide cover plate (UCL 284) andhinge fixing plates onto each of thehinge sections on the box.

Fit the second long piece of hinge as previously and slidecover plate and hinge fixing plate. Finally slide cover and hingefixing plate into last piece of hinge and secure as previously.

The Retro-Flex box is now ready for fixing to the front of theexisting sign box.

NOTE: the top of the Retro-Flex box should be securedwith bolts, washers and nuts to the top edge of theexisting sign box, The remaining three sides may besecured with self-tapping screws once all work has beencompleted to the face and interior of the sign.

Offer the Retro-Flex box up to the existing box and drill holesthrough the hinge/fixing plate and existing box at each endand at not more than 300mm centres around the perimeterof the box.

To fix cover plates drill 3.5mm holes at about 32mm fromeach corner and countersink to take No. 8 screw. Repeat atapproximately 700mm centres around the perimeter of thebox.

CornersExternal corners are fabricated in the same way as for thestandard system, using corner bars (UCL 326), puller bars(UCL 325) and castings, which fit into the ends of the vinylbars.

Vinyl bars should be square cut at the ends which are to formthe corner, For external corners cut vinyl bar at 30mm morethan the front edge dimension of the existing sign box.

Optimum corner illumination will be achieved by fitting avertical tube to the rear face of the reinforcing supportsnearest to the corner.

To open the Retro-Flex boxfor access to lighting tubesor electrics, remove all fixingscrews from the hinge fixingplates on THE BASE ANDBOTH SIDES of the sign. TheRetro-Flex box is now free toswing upwards and shouldbe propped open using suitablesupports whilst maintenancework is carried out.

Corners

Suitable Support

Vinyl Face PreparationNormal BoxCut vinyl to 216mm more than the dimensions of the vinylframe

Fold all edges to form a loop 38mm and stitch on all foursides of the face.

Cover Plate

108mm

38mm

Vin

yl Fra

me H

eig

ht

108mm108mmVinyl Frame Length

108mm108mm

38mm

Loop Stitched Here

Corners - ExternalCut Vinyl as Follows:

Length - cut vinyl to 271mm more than the length ofthe vinyl frame.

Fold all edges to form loop 38mm and stitch on all foursides of the face.

Depth - cut vinyl to 216mm more than the depth of thevinyl frame.

108mm Face

163mmFor tensioning, see FlexCaseStandard.

FLEXCASEFOR SINGLE OR DOUBLE SIDEDFLEXIBLE FACE SIGNS

For further information please contact:

Universal Aluminium Systems.Universal House.Pennywell Road,Bristol.BS5 0ER

United Kingdom

Tel: +44 (0) 117 955 9091 I Fax: +44 (0) 800 378 144mail to: signs@universal-aluminium.co.ukweb: www.universal-aluminium.co.uk

© Universal Components Ltd. April 2007