I saw Norm do some freehand signs a week or two ago. He'd gone to the company in NH that had originally made the NYW sign and talked to an expert. I've since tried it a couple of times with mixed results, but my needs were for 1/2" letters. I don't handle a router well enough for that size, so I ended up carving them out. I attached vinyl letters to the wood and then slowly chipped away the wood that was not covered by vinyl. I want a rustic appearance, but so far my results have been too crude to use.