A wearable sandwich board is two sign panels connected by straps that hang over your shoulders, one panel in front and one behind. You can build one in an afternoon with basic materials from a hardware or craft store. The standard size for an adult is 36 inches tall by 24 inches wide per panel, which is large enough to read from across a street but small enough to walk comfortably.
Materials You’ll Need
- Two sign panels: Corrugated plastic (often sold as coroplast) in 36″ x 24″ sheets is the go-to choice. It’s lightweight, rigid, and weather-resistant. Foam board works for indoor events but warps in humidity. Plywood or hardboard is durable but significantly heavier.
- Straps: Nylon webbing (1.5 to 2 inches wide) or sturdy ribbon. You’ll need about 6 feet total.
- Fasteners: Grommets, zip ties, or bolts with washers and nuts to attach straps to panels.
- Design materials: Paint, vinyl lettering, printed posters, or markers depending on how polished you want the result.
If you want adjustable straps, pick up two plastic or metal buckle sliders from a fabric or outdoor gear store. These let you fine-tune the hang length after the board is assembled.
Cutting and Preparing the Panels
If your coroplast sheets aren’t already 36″ x 24″, measure and mark them with a straightedge, then cut with a utility knife. Cut along the flutes (the internal ridges) when possible for a cleaner edge. Sand or smooth any rough edges so they don’t snag clothing or scratch skin.
For a lighter build, you can go smaller. A 30″ x 20″ panel still works well for someone under 5’6″ or for indoor use where people are reading from closer range. The key measurement is that the panel width shouldn’t extend more than a couple inches past your shoulders on each side, or you’ll clip doorframes and bump into people.
Attaching the Shoulder Straps
This is the structural heart of the project. You need two straps, each connecting the front panel to the back panel over one shoulder.
On each panel, mark two holes centered about 5 to 6 inches from the top edge and spaced roughly 14 to 16 inches apart (symmetrical from center). This spacing sits the straps comfortably on your shoulders without sliding toward your neck. If you have a grommet kit, punch grommets at each hole. Grommets reinforce the material and prevent the strap from tearing through over time. Without grommets, you can use bolts with large washers on both sides of the panel, or simply thread heavy zip ties through the holes and loop them around the strap ends.
Cut two strap lengths of about 30 to 36 inches each. Thread one strap through the left hole on the front panel and the left hole on the back panel, then repeat on the right side. The panels should hang so the top of the front panel sits at mid-chest level and the back panel mirrors it. Try the board on and adjust the strap length before you lock everything down. If you’re using buckle sliders, thread the strap through the buckle so you can tighten or loosen on the fly. If not, tie secure knots or bolt the straps in place once you’ve found the right length.
A common mistake is making the straps too long, which lets the panels swing and bounce when you walk. You want them snug enough that the boards stay relatively flat against your body, with just enough slack to move naturally.
Designing Your Message
Legibility at a distance matters more than aesthetics. For people to read your sign from about 25 feet away (across a typical street or parking lot), your letters need to be at least 2 inches tall. If you want readability from 50 feet, go with 4-inch letters. That means a short, punchy message works far better than a paragraph of text.
Stick to high-contrast color combinations: black text on white or yellow, white text on dark blue or red. Avoid script fonts or anything with thin strokes. Bold, blocky sans-serif lettering is easiest to read in motion. If you’re painting by hand, sketch the letters in pencil first using a ruler, then fill in with acrylic paint or broad permanent markers.
For a more polished look, design your message on a computer, print it at full size (most office supply stores can print 24″ x 36″ posters for a few dollars), and attach the printed poster to the coroplast with spray adhesive or double-sided tape. This gives you clean typography and the option to include logos or images.
Weatherproofing for Outdoor Use
Coroplast itself handles rain well, but anything printed or painted on its surface is vulnerable to moisture and UV fading. If you’re using the board outdoors, protect the design with a clear spray sealant. Several coats of a UV-resistant clear acrylic spray create a barrier against both water and sun damage. Let each coat dry fully before applying the next.
For printed posters glued to the panels, a layer of self-adhesive laminating film (available in rolls at office supply stores) provides the most reliable protection. It seals the entire surface against rain and prevents smearing. This is especially worth doing if you plan to reuse the board across multiple days or events.
If you’re caught without either option, clear packing tape overlapped in rows across the face of the sign works as a quick fix for a single rainy outing.
Comfort for Extended Wear
Even a lightweight coroplast board adds strain to your shoulders and upper back over hours. Two panels of 4mm coroplast at 36″ x 24″ weigh very little on their own (under 2 pounds total), but added paint, hardware, and decorations increase the load. Keep the total weight as low as possible, especially if you plan to wear the board for more than an hour or two.
Padding the straps makes a noticeable difference. Wrap the shoulder section of each strap with pipe insulation foam (the kind that comes in a tube you can slit open) or sew on fabric padding. This distributes pressure across a wider area and prevents the nylon from digging in.
Wear shoes with good support. You’ll be standing and walking, and the slight forward pull of the front panel changes your posture more than you’d expect. Take breaks when you can, and if the board is for a multi-hour event, consider adding a waist tie (a simple cord connecting the two panels at hip level) to keep them from swinging and reduce the strain on your shoulders.
Optional Upgrades
A few additions can take a basic sandwich board from functional to impressive. Battery-powered LED strip lights along the panel edges make the board visible after dark and draw attention in crowded settings. Adhesive-backed LED strips are inexpensive and easy to attach along the border of each panel.
If you need to change your message between events, mount a sheet of dry-erase laminate to one or both panels. You can write and rewrite with standard dry-erase markers, giving you a reusable board for different occasions.
For costumes or promotional events, consider wrapping the panels in fabric or attaching three-dimensional elements with hot glue. Just keep in mind that every addition adds weight and wind resistance if you’re outdoors. A flat, streamlined board is always easier to wear than one loaded with extras.