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.
Step 2: Sketch and burn designs onto the faces
We did Google searches to find images to use or fonts to pattern the blocks out of. Then lightly sketch those onto the face of the wooden block. Finally, we used an old tip on my soldering iron to burn the letters and designs into the wood. This part took the longest by far.
Step 3: Materials and tools
For this project you need:
Wood. Try for locally harvested rough-cut lumber that has dried for quite some time.
Saw. A table saw might work but I used my chop saw. BE CAREFUL! Use a push stick or clamps to keep your hands away!
Sander. Sand faces that you can before cutting to a smaller size and also be careful.
A wood burner or soldering iron.
Ideas. I had a hard time coming up with relevant and unique designs for some of the sides so get creative!