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Discussion Starter · #1 ·
I took on the job of reproducing a letter "M", which is about 12" tall and about 3" thick, to be set outside the customer's house. We are in Minnesota, so it will be subjected to hot/cold, wet/dry, freeze/thaw cycles.

I would like suggestions for what material will work best to make this letter "M".

The original was made out of 3/4" particleboard, glued and screwed together (not my work). It has bulged and is decomposing.

My first thought would be to use exterior sign plywood, glued together to get 3" of thickness, bandsaw out the shape, then paint it black and coat it with fiberglass resin.

Will that work, or do you have better ideas?
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