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When all letters had been cut, rounded and smoothed, put them on top of corresponding letters on outline. In this way, you can see bitten off or “chipped” part. The only solution you can make is to re-sand it.
The next step is to prime letters. Since foam is very light you will have to anchor them so that letters will not fly all over place. To do this, put letters on top of cardboard. Pin letters from back so you can prime whole front part. Priming involves several coating.
Sometimes you cannot prevent letters from breaking, especially in priming process. Glue broken parts together. When glue becomes dry, carefully smooth surface.
Then, start painting letters. Use a spray in painting. Choose a color that will not make any irregularities, like glued part, noticeable. Use push pins to hold letters during drying process.
You are now ready to make panel. Use a hard wooden plank. Trace shape of panel, and then cut wood. After cutting it, smooth surface and edges. Paint panel with varnish and let it dry. Draw design and outline on panel. Then paste letters on panel.
For additional information about the articles you may visit http://www.uprinting.com