Cutting out the alphabet

[Cooler]

Kydex is the only thing I can think of.  It is easily formed when heated. It is the stuff they use for formed holsters and it is the stuff they use for airline interior panels.   There are many videos online on how to use it.

https://www.youtube.com/watch?v=BUVhAKXm254

[Wild Turkey]

You're thinking too permanent.
  It's a stage prop, not a children's toy.

Spray adhesive to bond strips of poster board together for the outline.  Check the craft stores for something thicker yet pliable.  

Which letters are you using?  What font?  Different fonts will have different challenges in outlining.

Good luck and have fun!!!

[Rob Young]

That's a pretty impressive illustration you have there! Yes, that is pretty much exactly what I had in mind. I think I'd like the outer edge to be maybe 3" in thickness. Will a typical cnc cut that thick? I know of a couple of hobbyist guys nearby that have them. Maybe I'm underestimating the capability?

Some can cut that deep. But what I'd probably do is set up and cut layers and glue them up.

Edit to add, the rendering was done in Fusion 360 and took about 5 minutes to draw and maybe another 2 minutes to generate the rendering locally at high-resolution (which of course I have to knock way down so the graphics file is small enough for the WN forum to accept). 

Learning to use a "modern" 3D CAD software package has been a HUGE help both at work and in woodworking. I've never been very good at visualizing or sketching in 3D but this makes it pretty easy.

[goaliedad]

search you tube for “ask this old house letters”. Jimmy Derista did exactly what you are talking about

[ed kerns]

search you tube for “ask this old house letters”. Jimmy Derista did exactly what you are talking about

Really!? I will definitely check that out. Most of what I've seen on Youtube has been of styrofoam or poster board. The stuff that shows wood is very hard to watch for a woodworker. Thank you.
EDIT to say thanks again. That was the best YouTube video on the subject I've seen!

[ed kerns]

Some can cut that deep. But what I'd probably do is set up and cut layers and glue them up.

Edit to add, the rendering was done in Fusion 360 and took about 5 minutes to draw and maybe another 2 minutes to generate the rendering locally at high-resolution (which of course I have to knock way down so the graphics file is small enough for the WN forum to accept). 

Learning to use a "modern" 3D CAD software package has been a HUGE help both at work and in woodworking. I've never been very good at visualizing or sketching in 3D but this makes it pretty easy.

Thanks Rob. I'm a recently retired guy and learning some drawing program(s) is on my to-do list. I admire the talent.

[ed kerns]

You're thinking too permanent.
  It's a stage prop, not a children's toy.

Spray adhesive to bond strips of poster board together for the outline.  Check the craft stores for something thicker yet pliable.  

Which letters are you using?  What font?  Different fonts will have different challenges in outlining.

Good luck and have fun!!!

I've got a nagging feeling that you're right. It goes against my nature to build 'temporary' stuff, but I guess that is pretty much the definition of stage props. All it has to do is hang there and look good from 20 paces.

[ed kerns]

Kydex is the only thing I can think of.  It is easily formed when heated. It is the stuff they use for formed holsters and it is the stuff they use for airline interior panels.   There are many videos online on how to use it.

https://www.youtube.com/watch?v=BUVhAKXm254

I like that stuff! I've used it a time or two, and it would work, but probably too pricey for the amount I'd need for this project. Thank you.

[Wild Turkey]

I've got a nagging feeling that you're right. It goes against my nature to build 'temporary' stuff, but I guess that is pretty much the definition of stage props. All it has to do is hang there and look good from 20 paces.

I know how you feel.  LOML says I won't build something out of 2x4's if I can use a 2x6