How to create a custom shortened number plate

The current UK laws don't require number plates to have a minimum length, only a minimum margin on the sides of 11mm. This means that almost all of the excess on the sides of the number plates can be removed, producing a much smaller and cleaner looking number plate.

Shortened number plates are a vast visual improvement on many cars, especially when the registration is not long (5 characters, for example). Many customers request shortened plates for this reason, and some number plate suppliers produce 'one-size-fits-all' solutions for short number plates, be they 16 inch plates, or various other sizes.

Personally, we prefer to provide a custom shortened plate - it's a great USP (unique selling point) in comparison to the competition, and produces the best looking shortened plates every time. This guide explains how to create custom shortened number plates.

Tools needed

• Mitre saw
• High tooth count saw blade
• Angle grinder and cutting discs
• OR a bench grinder (alternative to angle grinder)
• Face visor and hearing protection
• Sanding blocks
• Plate Supplies number plate jig
• The Plate Supplies short plate length calculator
• Legal text in sticker form

Step by step

1. Use the Plate Supplies short plate calculator to calculate the length of the custom shortened plate, if the customer wants to know how long their plate will be. Enter their registration with the spaces as required.
2. Put a blank number plate into the Plate Supplies jig, and push the plate against the far left of the recess.
3. Measure 11mm from the leftmost edge of the plate, and draw a vertical line on the plate.
4. Position the spacer bar, so that the right edge of the bar is on the line. This is where you will place the first letter or digit.
5. Place all of the letters and digits as you normally would when creating a 3D gel or 4D laser cut number plate.
6. Place the spacer bar at the end of the registration and draw another vertical line.
7. Take the completed number plate over to your mitre saw, position it so the line on the right hand side of the plate is in line with the blade and using a slow and steady motion, cut through the line.
8. If there is any separation of the reflective from the acrylic, clear the area of any debris and push the reflective back on to the acrylic.
9. Using the side of the cutting disc on the angle grinder, add a very slight bevelled edge to the rightmost side of the plate, where it has been cut. Then, use the same technique to round the corners, in an attempt to emulate the standard number plate corners.
10. Using a sanding block, finish the newly cut edges and corners to produce a smooth final product.
11. Clean any acrylic dust from the plate and apply your legal text in sticker form. Company name and postcode in the centre, BSAU number in the bottom right corner.

Important notes:

• Always take great care when handling power tools, especially an angle grinder. Safety/personal protection equipment is a very smart thing to wear; you will regret not wearing it the one time something goes wrong.
• We use a cutting disc instead of a grinding disc on the angle grinder, as the grinding discs are too aggressive for the soft acrylic used on number plates. A cutting disc is hardy enough to grind the plate down slightly.
• 11mm is the minimum margin on the sides. If your customer needs a specific plate size, for example to cover screw holes in their bumper, use the calculator to see the length of their registration and add on the needed excess to the sides as requested.