Creating Large Wooden Letters For Your Wedding: A Step-By-Step Guide

Large wooden letters are a great way to add a personal touch to your wedding. They can be used as decorations, signposts, or even as a photo backdrop for you and your guests. Making your own wooden letters is a fun and budget-friendly DIY project that can be done in a few simple steps. You can choose any font and size you like, and even add lights to make them stand out. In this guide, we'll walk you through the process of creating your own large wooden letters for your wedding, from choosing the right materials to adding the finishing touches.

Choosing the right wood type and thickness for your letters

When selecting the thickness of your wood, consider the overall size of your letters and the desired level of sturdiness. For example, if you are creating tall letters, opt for thicker wood to ensure they stand securely. The thickness of the wood will also impact the overall weight of your letters, which is an important consideration if you plan to hang them or transport them between locations.

In the example provided, the creator used 16mm MDF for the front and back layers of their letters, with a 3mm MDF sheet on the perimeter. This combination provided the desired stability and monolithic look.

Another important consideration is the type of finish you plan to apply to your letters. If you intend to paint your letters, ensure the wood type and thickness allow for even paint coverage and a smooth finish. If you prefer a more natural look, select a wood type that complements your wedding theme and consider staining or sealing the wood to enhance its beauty.

Additionally, if you plan to add any decorative elements, such as lights or additional wooden layers, ensure the thickness of your letters can accommodate these additions without compromising stability.

Remember, the key to choosing the right wood type and thickness is to consider the overall design, functionality, and aesthetic appeal of your letters. By carefully planning and selecting the appropriate materials, you can create stunning wooden letters that will impress your guests and serve as a lasting memento of your special day.

Transferring your chosen design onto the wood

The first step is to choose your design and transfer it to the wood. You can make any design you want, but it's best to avoid thin traces and small radii to improve stability and make construction easier. Modify your chosen font to fit your needs and ensure it looks thick and solid.

Next, fit the letters into your wood sheets. You can do this by using paper templates or, if you have access to one, using a projector to transfer the design with a pencil. To ensure the dimensions are correct, introduce the letters into a square with the dimensions of the MDF sheet you will be using. This way, you can check for squareness and proper sizing by measuring over the wall and then transferring it.

Mark the intersection points and rough curves, and then refine the shape using a bandsaw blade as a "physical spline". This will help you achieve smooth curves using tangents and push points. You can use rulers and a heavy handplane to refine the curves.

Cutting out the letters and sanding

Now that you've chosen your design and transferred it to the wood, it's time to start cutting! This step is simple, but it requires careful attention to detail. Using a circular saw, make the big cuts for each letter. Then, use a jigsaw for refining the curves and smaller details. Don't worry too much if your cuts aren't perfectly straight—as long as you cut outside the line, it will be fine!

After the large cuts, it's time to refine and sand. The amount of sanding you'll need to do will depend on how careful you were with your initial cuts. Remember to wear a dust mask, especially when working with MDF! Cut and sand two sheets of MDF at the same time, refining just one of them. Once the first sheet is completely sanded and smooth, use it as a template to refine the other sheet. This will save you time and help ensure accuracy.

At the end of this step, you should have two equal faces for each letter, ready for the next steps of assembly and finishing.

Adding volume and structure to the letters

Now that you have cut out your letters, it's time to give them some volume and structure. In this step, you will be creating a recess in the inside face of each letter to attach the perimeter sheet. Use a router to remove about half of the thickness of the material, going deep enough so that the perimeter sheet sits flush with the surface of the letter. For example, if you're using a 3mm thick MDF sheet for the perimeter, you'll need to create a recess that is also 3mm deep. Remember to straighten any round inside corners with a chisel or a file so that your perimeter sheet sits snugly in place.

Next, cut some strips of particle board or wood to act as spacers. These strips will provide structure and stability to your letters, especially if they are tall or have curved shapes. Cut the strips to fit the specific needs of your letters and attach them to the inside of the letter using glue and brad nails. You can also add screws for extra reinforcement. These strips will help to create a sturdy framework for your letters and make it easier to attach the front and back faces together.

Once you have added the spacers, it's time to attach the front and back faces of the letters. Cut two equal pieces of MDF or plywood for each letter, making sure they match the shape of your letter exactly. You may want to use a template to ensure that both pieces are identical. Now, attach these pieces to the spacers using glue and brad nails. Make sure to align them properly so that the edges match up seamlessly.

If your letter has any small radii or curved sections, you may need to make some additional adjustments. Cut kerfs or parallel cuts into the wood to allow it to bend and form the curve. You can also use a jigsaw for refining and creating curves. Sand the wood as needed to smooth out any rough edges or imperfections.

Finally, you can add some finishing touches to your letters. Use a file or a hand plane to remove any excess material from the edges and round off the corners. You can also use a flush trim bit to eliminate any excess material from the faces of the letters. If you want a smooth and continuous look, consider using a round bit to create an edge fillet. Fill any gaps or imperfections with wood filler and sand the surfaces until they are smooth.

By following these steps, you will create large wooden letters with volume and structure that are perfect for your wedding or any other special event.

Painting and decorating your wooden letters

Choosing the Right Paint

First, decide on the type of paint you want to use. You can use latex paint, also known as acrylic paint, which is commonly found in craft and home improvement stores. It is a better alternative to oil or enamel-based paints due to its low VOC, fast drying time, and easy soap and water clean-up. If you are concerned about the smell, coverage, or clean-up of oil-based paint, latex paint is a good option. You can also find low VOC options at home improvement stores and higher-end paint shops.

Preparing the Surface

Before you start painting, it is important to prime the surface of the wooden letters, especially if they are made of MDF, which is very porous. A primer will help you achieve a smooth finish and ensure that the paint adheres well to the surface. You can use a spray paint or latex primer in a colour that is similar to your chosen paint colour. If you are using a dark paint colour, such as black, you may need to apply multiple coats of primer to get a medium grey tone before painting.

Painting Techniques

You can use a brush or spray paint to apply the paint to the wooden letters. If you want to avoid brush marks on the face of the letters, spray paint is a good option. Hold the can 6-8 inches away from the surface and use even strokes that start and end beyond the letters to prevent drips or build-up. If you are using a brush, go for thin, even coats and be patient, as it may take 2-3 coats to achieve the desired finish.

Adding a Protective Coat

Once you have finished painting, you can add a protective coat to your wooden letters. This step is optional but can provide extra protection and a bit of sheen to your letters. You can use a product like Mod Podge, which is a sealer that gives a glossy finish. If your paint already has a gloss or sheen to it, or if you are pressed for time, you can skip this step.

Decorating Ideas

There are endless possibilities for decorating your wooden letters. Here are some ideas to get you started:

• Confetti and Mod Podge: Create a fun and colourful decoration by covering the letters with confetti and sealing it with Mod Podge.
• Yarn-Wrapped Ombre: Wrap the letters with yarn in different shades to create an ombre effect.
• Photo Collage: Combine photos with the wooden letters to create a personalised monogram.
• Succulents: Fill the wooden letters with succulents to create a vertical garden with a message.
• Beads: Use wooden beads to cover the letters for a rustic and charming look.
• Glitter: Add glitter to the letters for a sparkly and festive touch.
• Stencils: Use stencils and paint or stain to create unique designs and patterns on the letters.
• Twigs: Trim twigs from your yard to fit the wooden letters for a natural and rustic look.

Remember, you can also combine different techniques and materials to create truly unique decorations. Get creative and don't be afraid to experiment!

Frequently asked questions