Thanks for all the tips on different ways to do the letters. Many of
you have responded with excellent I think the easiest
advice to try is the idea of buying the message board letters. The
kind you see on hotel signs. This is Andrew Martin's idea that I've
read about soon after posting the original question. That is an very
economical way to try it.
They are laser cut, inexpensive, and can easily be spaced. The may
or may not have a draft, but at 15 dollars for 160 letters, there is
nothing to loose.
My last issue is the metal choice. Since I'm casting some what
larger items than I've ever casted before, I need to make things as
easy as possible. I have cast bronze up to half of a pound. Small
With these plaques, they may be twice as big. I read a melting
temperature chart of metals from the Engineer's ToolBox website and
it claims that Aluminum-Bronze melts at only 1190 to 1215 Degrees F.
Here is the link.
Not only would such a low melting temperature be an easier set-up
for me, but Aluminum-Bronze is a very easy alloy to make yourself
since you don't need to find tin.
But is that a typo? I tried looking up other sources and non of the
available Aluminum-Bronze alloys have a melting temperature that
low. The most popular Aluminum Bronze alloys have a typical bronze
melting temperature that is much higher.