Msg from daughter "I need a "P"". OK. This will make number 52 built since this time last year.

The size is 32w x 48 long but my CNC only allows 37x25, so I create my files in VCarve Pro using the tile feature. Then I have two 32 wide x 24 tall. The end result is a shape cutout of 1/2 inch Birch plywood with a 1/8th compression bit. Final size is 32 x 47 inches.

With the shape positioned on the work table, I use a 1/8th round-over bit to ease the edges of the light socket holes (on both sides). Then cut and fit with glue and brad nails 3/4 inch x 3 7/8 inch sides. Fill the nail holes and a little caulk here and there and this "P" is ready for paint and lights. Fortunately, that is not my job. :) Finished examples included.

Looks like you've cornered the market on marquee letters, Well done!

You've got this down to a science Mike. Well done.

I see a 4 x 8 table in your future.

More shop space would be great. Basically, I stand in one spot (or nearly the same spot) as I assemble these letters and numbers. Measure, turn around, cut the length and angle. Turn back around and glue and nail it in place. Repeat :)

42 minutes ago, MT Stringer said:

More shop space would be great. Basically, I stand in one spot (or nearly the same spot) as I assemble these letters and numbers. Measure, turn around, cut the length and angle. Turn back around and glue and nail it in place. Repeat :)

More shop space just means less efficient production. If it works then don't change it. ;)