What kind of material is that? Looks awesome!
Nice work. I would not have tried those letters using regular wood. Good quality plywood will hold together much better and minimize the number of tabs required. When I paint the inlays, I do not offset. If one struggles to fit, I just touch it up with the Dremel.
Yes, either pick through at big box (Lowe’s seems to be better than Home Depot) or bite the bullet and get Rockler - should be no gaps or you can return it… Or, the recycled stuff from old cabinets and drawers is usually awesome.
I’ve never tried it but I have seen great pictures on this forum.
Expanded PVC cuts like butter, especially with a Spiral O bit…if you paint the pvc paint both
sides as it will warp if you dont