A few friends and family members have been expecting and I decided I wanted to make a custom set of wooden letter blocks to give to them as a gift.
As a bonus, these blocks are made from the cast-offs from a lumber mill. They are made from Western Yellow Cedar so smell great and by wood-burning and avoiding paints they are non-toxic.
Step 1: Make blocks
The yellow cedar I used were materials that were left over from a large order and had sat out in the weather for years. To bring them back to a nice condition I used my hand planer, belt sander and chop saw to create blocks of wood that were almost two inches square. I used the thickness of the board to determine the size of the block and honestly found that a little variation was nice to have. They are not perfectly square but close enough.
In about an hour I could cut 30 blocks (enough for a few errors) and sand the faces and edges to make them suitable for the next step.