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
I also learned from this step that when cutting out the letters by hand they look better when they are spaced farther apart.