I've done a dozen or more of these letters now. Each letter has to be cut differently, but they are all made from 2x4s and pocket holed together using my Kreg Jig. I have also made some letters with curves (such as R, B, J, etc). I cut the curve out of a 2x10, left over stair stringer and then join it with some 2x4 for the rest of the piece. To make the base plates, I cut small blocks of 1x3 and rounded the edges with a palm sander. I used glue and finish nails to attach them. I have more projects like this on my blog http://pneumaticaddict.blogspot.com .
Estimated Cost
$4
Estimated Time Investment
Afternoon Project (3-6 Hours)
Finish Used
I wanted them to look very rustic, so I purposely didn't sand or use wood filler. First I painted them with 1 coat of acrylic paint a little brighter than my desired shade. I then glazed each letter with a dark brown glaze. Next, I white washed selected areas to add highlights. I distressed the edges with 100 grit sandpaper and sealed the whole thing with 2 coats of Polyacrylic in Satin.
Recommended Skill Level
Intermediate