Lead Foot CrossFit wanted a distinctive exterior sign that reflected its automotive-inspired branding while remaining bold, readable, and visually effective both day and night.
Designed the sign in CAD, developed the aluminum and translucent-acrylic construction, engineered the halo and face-lighting layouts, fabricated the individual components, completed the low-voltage wiring and assembly, and installed the finished sign on the building.
A one-off illuminated sign combining black halo-lit LFX letters, a face- and halo-lit speedometer gauge, and illuminated push-through CROSSFIT lettering for strong daytime contrast and a layered nighttime appearance.
Overview
Lead Foot CrossFit wanted an exterior sign that felt like part of the brand rather than a standard illuminated sign package. The design takes inspiration from an automotive gauge cluster, combining bold black LFX lettering with an illuminated speedometer-style gauge and push-through CROSSFIT lettering.
The project was designed as a complete custom assembly, with the structure, lighting, materials, electrical layout, fabrication methods, and building attachment developed around the final appearance.
Design & Engineering
The main LFX letters were designed as fabricated aluminum assemblies with black faces and concealed rear-facing LEDs to create a halo against the building. A large translucent gauge provides both face illumination and halo lighting, while the CROSSFIT lettering uses thick push-through acrylic for a dimensional illuminated face.
Several details had to be considered beyond the appearance of the sign, including LED spacing and diffusion, cabinet depth, acrylic thickness and thermal movement, wiring access, weather sealing, mounting to an EIFS façade, and maintaining serviceability after installation.
The finished lighting system uses separate face- and halo-lighting circuits with the power supplies located inside the building, allowing the exterior assemblies to remain clean and compact.
Fabrication
The sign combines fabricated aluminum, translucent sign acrylic, polycarbonate, vinyl, LED modules, bonded and mechanically attached components, and custom mounting hardware.
The aluminum exterior was finished black while the interior surfaces were kept reflective to improve light distribution. The acrylic components were selected and arranged to diffuse the individual LED modules while maintaining the crisp appearance of the graphics during the day.
Individual assemblies were wired and tested before installation to verify illumination and minimize service work once the sign was mounted.
Installation
The completed assemblies were installed on the building’s EIFS façade. Mounting, electrical penetrations, spacing, and weather sealing were planned as part of the sign design rather than treated as separate installation details.
The approximately one-inch wall standoff behind the halo-lit elements creates the depth needed for the rear-facing LEDs to produce an even glow around the black aluminum faces.
Outcome
The finished sign combines several illumination techniques in one cohesive assembly: halo-lit lettering, a face- and halo-lit gauge, and illuminated push-through acrylic.
During the day, the black aluminum and white translucent elements provide strong contrast. At night, the separate illuminated layers give the sign significantly more depth and visual presence while reinforcing Lead Foot CrossFit’s automotive-inspired identity.
