You might try using a solid wood as opposed to plywood. That should cut down on the "fuzz effect" you are getting with your router. You might try one of the big craft store chain's like JoAnn's or Michael's for basswood. They also have a large selection of wheels, clothing pegs and other wooden dodads for less than most woodworking specialty stores. Note: I checked today and JoAnn's has 6" x 3/4" thich wooden letters for $2.50 each. These have an ogee bevel and numbers are also available.
Last edited by Mike; 11-24-2004 at 07:38 PM.
Reason: More info