| > People that rout signs often use either a "V" groove or core box bit.
| This is good advice, as over the weekend, I will try anew.
| I want whatever is easiest to control in very soft wood, so, I will
| try the V-groove.
It seems like you're making an awfully big job out
of this. Controlling a router freehand to make letters
is going to be nearly impossible. Even routing a straight
line against a fence is tricky. The bit tends to wander
and a wood with rough grain, like fir, will cause it to
wobble. Using a dremel tool might be more realistic,
but still not easy.
Then once you've routed, then what? Are you going
to squeegee white paint into the grooves? That's a
tricky job, too, if you want it to look good.
Why not just use a permanent marking pen? If that
doesn't look official enough for a school bathroom pass,
you can get stick-on letters at Home Depot for about $3.
If that seems not durable enough you could coat them
with polyurethane or acrylic resin.
For any of those options you'll probably need to first
paint the wood a light color. The piece you have looks
like it's a scrap of pine stained with very dark "walnut"
stain. Ugly. Hard to see. And requiring you to use light-
On the other hand, why not just use a fresh piece of
wood? You could get a pine 1x2 for a couple of dollars,
stick on black letters, then polyurethane the whole
thing. Then you'll have a nice looking pass that looks
official, and the kids won't need two hands free to carry it.
All for less than $10 if you have polyurethane on hand.