Animated Noel Sign
Here's a project that's easy and fun to build, yet large enough to span nearly the full width of a garage door. The finished display combines a continuously illuminated “NOEL” sign with three independently animated bells.
A video of the completed display can be viewed HERE.
Overview
This project uses the spring grid from an old queen-size mattress as the structural frame. Rope light forms the word “NOEL” and outlines three bells made from 9-gauge galvanized wire.
The original display used four lighting channels:
- One channel for the “NOEL” lettering
- One channel for each of the three bells
The lettering remained continuously illuminated while the bells were animated in sequence.
Materials and Tools
Materials
- Spring grid from an old queen-size mattress
- 9-gauge galvanized wire
- Rope light
- Transparent Metalcast paint, if colored rope light is desired
- Black electrical tape
- Heavy-duty zip ties
- Four-channel controller or equivalent
- Electrical wire and connectors appropriate for the selected lighting system
- Mounting hardware suitable for the installation location
Tools
- Wire cutters
- Pliers
- Welding equipment
- Safety glasses
- Work gloves
- Basic electrical tools
- Drill and mounting tools as required
⚠️ Warning:
Old mattress frames and cut wire can have sharp edges. Wear gloves and eye protection while dismantling the mattress and forming the wire. Use appropriate protective equipment while welding.
If AC rope light is used, all wiring, connectors, enclosures, and controllers must be rated for outdoor use and protected by a GFCI circuit.
Controller Options
The original project used a DIGWDF 675-Plus controller. That controller is not required, however.
Any controller capable of independently switching four lighting circuits may be used:
- An AC controller for AC rope light
- A DC controller for low-voltage LED rope light
- A modern pixel or RGB controller if the design is adapted to addressable lighting
The original arrangement used one channel for the word “NOEL” and three channels for the bells.
Preparing the Mattress Frame
Dismantle the mattress and remove the large spring grid that forms the internal support structure.
Remove any fabric, foam, padding, staples, clips, or other material attached to the spring frame.
Inspect the frame carefully for sharp wire ends, broken welds, or loose pieces. Repair or remove anything that could create a safety hazard.
The mattress spring grid becomes the foundation for the entire display.
Building the Bells
Form three bell outlines from 9-gauge galvanized wire.
Each bell should be formed and welded as a separate piece. Keeping them separate makes the bells easier to shape and allows them to overlap when attached to the main frame.
The bells do not need to be identical, but their overall size and proportions should be similar enough to appear as a coordinated group.
💡 Note: Equivalent wire may be substituted if it is stiff enough to hold its shape and suitable for welding or mechanical fastening.
Forming the “NOEL” Lettering
Lay the mattress spring frame flat on a work surface.
Arrange the rope light across the frame to spell “NOEL.” Cursive lettering was selected for the original project because it required fewer sharp bends and was easier to form than block lettering.
Secure the rope light to the spring frame with zip ties.
Use enough ties to maintain the shape of the letters without crushing or sharply bending the rope light.
Sections of rope light that must pass between letters or cross the display without being visible can be covered with black electrical tape.
⚠️ Warning:
Do not cut rope light except at the manufacturer’s approved cutting intervals. Cutting it at the wrong location may damage the light or create an electrical hazard.
Adding Rope Light to the Bells
Attach rope light around the perimeter of each wire bell.
Use zip ties at regular intervals to hold the rope light firmly against the wire frame.
Avoid tight bends, kinks, or stress near electrical connections.
Once the rope light is installed, attach the three bells to the mattress spring frame. Arrange and overlap them as desired.
The overlapping bells provide visual depth and make the large display more interesting.
Coloring the Rope Light
Transparent Metalcast paint may be sprayed onto clear rope light to create bright colors while still allowing light to pass through.
Mask any areas that should remain unpainted, including electrical connections and portions intended to stay clear.
Apply several light coats rather than one heavy coat, allowing each coat to dry according to the paint manufacturer’s instructions.
Test the paint on a short unused section of rope light before applying it to the completed prop.
💡 Note: Paint compatibility can vary between rope-light jacket materials. A small test area should always be checked before painting the entire display.
Installing the Controller
Mount the controller to the rear of the spring frame or in a nearby weather-resistant enclosure.
Connect the four outputs as follows:
- Channel 1 — “NOEL” lettering
- Channel 2 — Bell 1
- Channel 3 — Bell 2
- Channel 4 — Bell 3
Secure all wiring so it cannot rub against sharp metal edges or pull loose while the prop is being moved.
Use strain relief on all power and signal cables.
Original Animation Method
The original DIGWDF 675-Plus firmware was configured so that Channel 1 remained continuously on while Channels 2, 3, and 4 animated the three bells.
When the controller was powered:
- The word “NOEL” illuminated and remained on
- The three bells animated independently
The controller therefore operated as a self-contained display without requiring a separate show computer.
Original Firmware
The original firmware for the 12F675 chip is preserved below for historical use and reference. Both the assembly source and HEX files are included.
Modern Control Options
The original four-channel animation can be reproduced with many modern controllers.
Possible alternatives include:
- A four-channel AC lighting controller
- A low-voltage DC controller
- An ESP8266 or ESP32-based controller
- ESPixelStick
- WLED
- xLights-controlled outputs
- A small standalone sequencer
The lighting technology may also be updated while preserving the original design.
Possible modern lighting alternatives include:
- LED rope light
- Flexible LED neon
- RGB rope light
- Pixel strip
- Seed pixels
- Other addressable LED products
When converting to addressable pixels, the lettering and bells can be divided into virtual segments and animated with far more flexibility than the original four-channel design.
Mounting and Installation
Because the completed display is nearly the width of a garage door, plan the mounting method before beginning construction.
The mattress spring frame provides many useful attachment points for brackets, hooks, wire, or other hardware.
Mount the prop to a structure capable of supporting its full weight and resisting expected wind, snow, and ice loads.
⚠️ Warning:
This completed prop is large and somewhat awkward to handle. Plan on having two people available when moving or installing it. Be sure the support frame and attachment points are strong enough to withstand wind and winter weather.
Route power and control wiring so it does not create a trip hazard or interfere with the operation of the garage door.
Completed Display
The finished display is large, bright, and easily visible from the street. It demonstrates how recycled materials can become the foundation for a substantial animated Christmas prop.
Storage and Maintenance
Inspect the display before each season.
Check for:
- Broken zip ties
- Cracked or damaged rope light
- Loose electrical connections
- Rust or broken welds
- Damaged insulation
- Worn mounting hardware
- Sharp wire ends
Replace damaged zip ties with outdoor-rated or UV-resistant ties.
Store the display in a dry location where the rope light and wire frame will not be crushed or sharply bent.
Lessons Learned
- A recycled mattress spring frame provides a large, strong, and inexpensive prop foundation.
- Cursive lettering is easier to form with rope light than block lettering.
- Separate bell frames make shaping and installation easier.
- Black electrical tape can hide unwanted illuminated sections.
- Transparent paint can add color to clear rope light.
- Four independently controlled channels are enough to create a convincing animation.
- Large props should be designed with mounting, handling, and storage in mind from the beginning.
Final Thoughts
This project is a good example of turning discarded material into a large animated display element.
The original design remains practical, inexpensive, and easy to understand. It can be reproduced with traditional rope light and a simple four-channel controller or updated with modern LEDs, pixels, WLED, ESPixelStick, or xLights while preserving the original appearance.