I had an order to make this board for a friend so his grandkids could learn their last name ( KOENIGSKNECHT). At work we called him Tim K-13.....quite a handle,
The letters were cut on on scroll saw out of 1/4" Baltic Birch plywood. I scored them first om my CNC laser- it will not cut this thick of material. I did the name in 3 pieces (so I could swing them in the scroll saw) and they were glued on a piece of 5/16" Baltic Birch. They fit pretty snug so I did a lot of sanding on the letters and the openings so they were very loose in their pockets. Tim is going to paint it. I added a lot of notches so the letters could be picked out if necessary. The K,'s, N's and E''s had to be fitted so they work in both locations.
Cheers, Jim