After about 5 days worth of work, I've completed our new Merry Christmas Sign!! It is about 50 ft long and close to 4ft high. Our old one was made out of PVC pipe that formed the individual letters using incandescent light bulbs. It was a complete pain to put up every year and ate away at our time that could be used for other decorations.
My Dad was at his second home "Menards" and came across their green painted fencing that was 50 ft long with 2" x 4" squares. Bought our lights from Home Depot as they had the best price for continous on LED lights for $11 (with tax). This allowed me to unplug any unused lights to give that nice distinct definition of each letter. Each light was zip tied twice to stop the lights from twisting, especially with storage. Which, in the end can just be rolled back up and tucked in away in a corner. 3 things I would have done differently is:
Capitalized the R's as I already have gotten crap for it by 3 people.
If we had more money and more experience, probably would have used rope light
Did 4" spacing instead of 2" for the MERRY section. I'll probably fix this next year by just moving the MERR back as there is over 1 ft of space to work with before the M
My fingers hurt, bled, and went numb from all the zip tying, but now I have calluses a professional guitarist would be jealous of haha.
1624 Zipties (I zip tied the unused lights as well to keep them from hanging)