"Karl Townsend" wrote in message
anews.com...
The roadside signs announcing my business need replacing...

With a huge laborious effort, I now have the sign as an AutoCAD file. My
next step is to have the lines burned/cut into a material so I can make a
stencil. There are a few sections in the sign where the stencil will be
only 1/2" wide and a lot where the stencil will be 1" wide. The sign
measures 48" by 96" (4'x8').
snip

How about a piece of 1" 11-ply have a sign shop use your file to cut the
letters out of rubber sheet. Stick the rubber on the ply and sand-blast it
to 1/2" deep arounf the letters. Seal and paint the **** out of it or stain
and urathane it. It will last forever...with fresh paint or urathane once
in a while.