How to Retrofit Old Traffic Signs and Remove Reflective Sheeting: A Complete Guide

When road information changes, existing traffic signs often need to be updated. This retrofit process may involve simply changing street names or completely replacing the graphic layout. One of the most challenging tasks for traffic sign manufacturers is removing old reflective sheeting - a question we hear from customers regularly:

"How can I remove reflective film from a traffic sign?"

"The reflective sheeting won't come off - what should I do?"

"How do I cleanly peel reflective film off an aluminum sign?"

This article outlines three effective methods for removing reflective sheeting and retrofitting old traffic signs based on your specific project requirements.

Why Is Reflective Sheeting Hard to Remove?

Reflective sheeting is designed with permanent adhesive for long-term outdoor durability. The adhesive is not meant for repositioning or removal, which makes retrofitting old signs a difficult task. However, with the right tools and methods, it can be managed.

Method 1: Partial Content Change (Text-Only)

If the update only requires changing the text or part of the graphic, follow these steps:

Disassemble the sign panel from its frame and lay it on a clean flat surface.

Use a heat gun or industrial hot air blower to gently heat the lettering area. This softens the adhesive.

Slowly peel the old text film using a scraper or plastic blade.

Remove adhesive residue with alcohol or adhesive remover. Repeat as needed.

Dry the surface thoroughly before applying the new cut vinyl letters.

✅ This method is cost-effective and preserves the original reflective background.

Method 2: Full Reflective Sheeting Removal

For signs requiring complete removal of the reflective background, you'll need more advanced equipment:

Use a high-pressure water jet to remove the reflective sheeting. This can strip off large sections without damaging the aluminum base.

Wipe off remaining glue residue using industrial alcohol or solvent cleaner.

Let the surface dry completely before applying new reflective sheeting and graphics.

⚠️ This method requires specialized tools and is usually done in professional sign workshops.

Method 3: Apply New Film Over the Old One

If the full removal method is not feasible (due to lack of equipment or high labor costs), you can overlay new reflective sheeting on top of the old one:

Remove only the original text graphics - if not removed, old lettering might remain slightly visible through the new film.

Clean and dry the old reflective surface thoroughly.

Apply a new reflective base layer, then place the new text/graphic film on top.

❗This is a last-resort solution and should only be used for non-critical or temporary signs, as layered films may slightly reduce reflectivity or result in uneven surfaces.

Summary Table: Old Sign Retrofit Methods

Final Thoughts

Traffic sign retrofitting can be time-consuming, especially when dealing with permanent adhesive reflective films. These films were never designed to be removed - which is why removal is often one of the most challenging tasks for manufacturers.

Whether you're replacing outdated road names or upgrading the entire sign surface, choosing the right removal method will reduce cost, save labor, and ensure your new signage performs reliably in the field.

Need help choosing the best materials or retrofitting service? Contact our team for tailored guidance and professional support.