If you want to make a letterhead, think of a unique and pleasing design that would fit nature of your business. Search on effective letterheads to serve as your guide.Consider making a letterhead with raised letters that are rounded on front. For materials, you will need foam, sandpaper, scroll saw or cutter, spray paint, varnish, cardboard, carbon paper, push pins and wooden plank for panel. In making outline, you can use Corel Draw or any other computer graphics programs.
After making layout, start printing letters. You can either manually draw it or make use of computer if you wanted a fast and accurate output. Print letters individually on a carbon paper so that you can easily trace them on foam.
After plotting letters, use a scroll saw or cutter to cut them. This step is quite difficult because there is a possibility that letters will be deformed. Make sure that back sides of letters are well shaped and flat. For front, you will have to round it.
Sanding of letters is very time consuming. In this step, use a sand paper to smooth-even letters and to make curves for front side.
Have a copy of outline of design. You can print it on a plain white paper. Fill letters with dark colors so that it will be easy for you to determine irregularity in shape of sanded letters. Make letters on your outline a little larger so that you can easily see difference.