I made this sign for my sons room using the 30x30 longmill and Easel Pro by inventables. I face laminated recycled pressure treated deck boards in the herringbone pattern onto a 1/4" plywood substrate. I used the inlay generator on easel to inlay 2mm into my board so gluing/ lining up the letters would be as easy as doing one of my sons puzzles. Then I cut the letters out of 5/8" MDF and spray painted. I finished it off with rabbeting a frame so the panel would drop in from behind.
My learnings: When cutting all the way through, cut a hair more than you think. I spent a good hour cutting out the letters that didn’t quite penetrate though with an OLFA. Seal the edges on freshly cut MDF if you plan on spray painting, that stuff is a sponge. Lastly, take you time and enjoy it. Don’t get too stressed over the hiccups along the way as I did.
This experience was great to learn from so I can pass on the knowledge to my students!