A big letter a - almost 18"x24"
Made of wood.
Etched with laser engraver, but you could draw it out.
Cut with scroll, coping, or jig saw
finish sand and seal or decorate.
Step 1: Design The Letter
The cutting surface of the Epilog Helix Laser I used was 18"x24"
I cut a sheet of 1/2" Plywood to 18"x24" to fit.
you could also draw the letter directly on your wood if you like
Step 2: Print the letter
Depending on the wood you use and the power of the laser, you can use it to trace or cut the image into the wood.
My 1/2' plywood was too thick for this laser, so the image was burnt in and used as a cutting guide.
Step 3: Cut wood letter out
A coping saw or jigsaw will also work if you prefer.
Cut the letter out along the outline.
Drill a hole in the inner waste area to open a space for your saw blade.
Step 4: Finish sand the letter
I used the belt sander for the outside edges and hand sanded the inner areas.
Finish sand the face with a block or finishing sander.
Step 5: Decorate your letter
Step 6: Add hanging hardware
I chose to drill a hole at an angle so it would grab a nail head and hang flush with the wall.
Be sure not to drill too deep and cut through the front!
Step 7: Enjoy your new letter
I made this project at the Tech Shop in Menlo Park.