Doubling the size of a LED sign

 I have two 40" by 16" LED signs. Each one has five by two of the 32 by 32 P6 LED arrays. I thought they were identical signs and thought that I could combine them to make a sign twice as big.  The first issue is the height, I am limited to 2 feet of height.  So the options are 7 by 3 or 6 by 3 LED arrays.  For 7 wide I need one more LED panel so I tested it with a spare panel that apperared to match.  Well, two of the existing panels had a bad LED and the odd panels blue color was a real mismatch.  So 6 by 3 is the best arraingement.

The next problem was that one sign had 35x35 LED's and the other had 27x27 LED's.  However in a test setup they completely match in colors and intensity except in the lowest brightness settings. So that problem can be ignored.

The next problem is extending the exrtrusions to make them wider, instead of 40" wide I needed 48" wide.  I designed and printed a 3D part that fits inside of the extrusions to allow two extrusions to be joined together.

The next problem is that one sign used magnetic devices to hold the panels to the braces but the other sign used double sided foam for that purpose.  I decided to use some of the magnetic holders and to design and print my own spacers for the rest of the sign. This holder can be used to space the panels back to match the extrusion but if you are using a 3" by 1" aluminum frame it can be reversed to space the panels back from the front edge.

This picture shows the center strip where magnets fasten the panels to the Metal.  However the magnets do not work and plastic wire ties were needed to hold the panels in place.

This picture shows the power supply mounting arrangement. There are three power supplies of 40 amps each.

This picture shows the spacers that fasten the panels to the extrusions.  Also you can see where two extrusions were fastened together in this picture.