If you are wrapping your returns rather than welding them like a reverse channel letter, than the standard offset is 1/8".
1/4" to 1/2" offset is a reflection on the forming itself.
If you need that big of an offset, your returns are not being formed properly.
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Hello
I do not know what type of construction you are doing to produce your letters. but we weld our letters to the back with the return sitting on the letter it self and we add .080 to the face. if you are riviting the returns then you have to add the thickness of the return then add .080 for the face. for example .040 returns X 2 = .080 plus the .080 for the face. if you are welding your letters then only add the .080
Good luck
Mike
Nowak Signs
1-877-808-1520
nowaksignsmfg@aol.com
www.nowaksignsmfg.com