Cut the 1×3 board to your desired length for each letter ledge row. Next, set the height of your table saw blade to 1″. Then, set the width of the glide rail to 3/8″. Pass the 1×3 through the table saw blade to create a 1″ deep channel. Finish/Stain as desired.
My favorite finish combination:
Set the height of your table saw blade to 1/4″. Then, set the width of the glide rail to your desired letter card length. I ripped an 11×14 acrylic sheet into 10 – 2.75″ x 5 1/5″ cards, so I set the glide rail at 5 1/2″. Rip down the acrylic sheet into two equal lengths. Then, use the miter saw to cut the width of each letter card. Sand any rough edges down with 220 grit sandpaper and removed the acrylic sheet protector.
*Note: Always account for the 1/8″ blade thickness. Also, when cutting the acrylic sheet, be sure to go as slow as possible to prevent chipping.
Use your Cricut or vinyl cutter to cut out letters in the vinyl sheets. I used the font GoBold and made the letters each 3″ in height. Once your letters are cut, apply them to each letter card. Make sure the letter card is free from debris, and account for 1″ that will be hidden by the wooden letter ledge row. It also helps to lay a grid underneath the letter card surface to help visually align all the letters the same.
Finally, insert your letter cards into the letter ledge row and figure out the spacing for each row. Use a finish nailer to tack each row onto your wall. Be sure to nail the bottom of the board only. You don’t want to nail through any of your cards. Enjoy!