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You could print the letters from the computer and freehand rout them with a sign carving bit.
Hello,I'm looking for a source for 4" letter templates for use with a router, so far I can't seem to find anything that large. I would like to rout "TOYS" in the front of a toy box I'm building for my son. Another option would be a CNC'd template that could be used with a 5/8 guide bushing if anyone has a source for that. All the CNC sites I found online appeared to be geared towards large scale production and not really "one-off" type of work. I'm located in Maryland if anyone knows any local sources. Thanks in advance for any help. -Jon