How to Make 3D Letters for the Home.
http://www.craftsforum.co.uk/showthread.php?24547-3D-letters-wanted I put a comment on this forum with a link to this post.
www dot arro-signs dot co dot uk/blog/how-to-make-3d-letters-for-the-home/
Buy a sheet of MDF, cut a card template of the letters that you want to make. Stick them to the MDF. Use a scroll saw to cut the letters using the card template as a guide. If you want thick MDF letters, cut more letters and glue them together with epoxy resin. The edges of the letters will probably not line up perfectly so you will need to use a filler to get rid of the ridges, use car filler it work really well. Sand the edges to a smooth finish. Paint using car spray high build primer, sand back each layer, about 3 layers should do it, now paint up with a gloss car spray.
If you want to use these letters outside, prime the letters with 2 layers of exterior grade PVC, before painting.
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