In this instructable I share my tips and tricks for making a stencil or a sign using the following materials:
tube of cardboard from blick 15' (30" wide) for ~$2.00
vinyl cutter at Techshop SF
stencil cutting knife
The process that I am developing is to make it easier to create a lower cost stencil that gets better with use. Some stencils fall apart after a few uses and some get better with use as they harden up from the extra paint.
Created in October 2013 by SFlettering
I made it at Techshop http://techshop.ws
Step 1: Test Cuts and Scoring the Cardboard for Manual Cutting
For the first round of experimental stencil making I used the vinyl cutter to "score" the cardboard and provide lines for later cutting manually. Although this technique worked I found that it duplicated the total effort and did not produce the crisp lines desired for a stencil.
I also learned from this step that when cutting out the letters by hand they look better when they are spaced farther apart.