Consider making a letterhead with raised letters that are rounded on the front. For the materials, you will need foam, sandpaper, scroll saw or cutter, spray paint, varnish, cardboard, carbon paper, push pins and wooden plank for the panel. In making the outline, you can use the Corel Draw or any other computer graphics programs.
After making the layout, start printing the letters. You can either manually draw it or make use of the computer if you wanted a fast and accurate output. Print the letters individually on a carbon paper so that you can easily trace them on the foam.
After plotting the letters, use a scroll saw or cutter to cut them. This step is quite difficult because there is a possibility that the letters will be deformed. Make sure that the back sides of the letters are well shaped and flat. For the front, you will have to round it.
Sanding of the letters is very time consuming. In this step, use a sand paper to smooth-even the letters and to make the curves for the front side.
Have a copy of the outline of the design. You can print it on a plain white paper. Fill the letters with dark colors so that it will be easy for you to determine irregularity in the shape of the sanded letters. Make the letters on your outline a little larger so that you can easily see the difference.
When all the letters had been cut, rounded and smoothed, put them on top of the corresponding letters on the outline. In this way, you can see the bitten off or “chipped” part. The only solution you can make is to re-sand it.
The next step is to prime the letters. Since foam is very light you will have to anchor them so that the letters will not fly all over the place. To do this, put the letters on top of the cardboard. Pin the letters from the back so you can prime the whole front part. Priming involves several coating.
Sometimes you cannot prevent the letters from breaking, especially in the priming process. Glue the broken parts together. When the glue becomes dry, carefully smooth the surface.
Then, start painting the letters. Use a spray in painting. Choose a color that will not make any irregularities, like glued part, noticeable. Use push pins to hold the letters during the drying process.
You are now ready to make the panel. Use a hard wooden plank. Trace the shape of the panel, and then cut the wood. After cutting it, smooth the surface and edges. Paint the panel with varnish and let it dry. Draw the design and outline on the panel. Then paste the letters on the panel.
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