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Pete C.

wrote:

I always just draw the pattern directly on the substrate then paint
with a brush. Thats the way the sign painters do it and it makes a
superior product.

If he has it on computer already, he could just get his hands on a
projector, project the image onto the sign substrate and trace the
outlines.

Of course, instead of doing it this way, if he finds someone with CNC
plasma he could have them cut the characters from sheet metal, add some
weld studs, powder coat and then attach to the substrate and have
something that should last a long time.