Here’s a nifty tip from Canadian Woodworking (don’t forget to visit their site!)
by Ted Duquette
Here is how I make lettering templates out of 1/16″ plexi- glass. I use a computer to print out the lettering patterns first (you could also draw them by hand). The trick to cutting Plexiglas successfully is to buy the type that has the brown paper on both sides of the Plexiglas.
You can glue your pattern on to the brown paper or you can draw the lettering right onto the paper. I use a #5 scroll saw blade with 12 teeth per inch to do the cutting. I set my saw at about half speed. If you only have a full speed saw, it can still be done but you will need to take a lot more care to ensure clean cuts. Take your time when cutting out the lettering – remember this will be the master template for all your future lettering. If you can’t get the brown papered version use un-backed Plexiglas. However, before you start cutting cover the glass with masking tape. This helps cool the blade while cutting so the Plexiglas doesn’t melt. I have made about two dozen of these lettering guides in different sizes and fonts and use them a lot in the shop.