DIY Custom Oversized ΔΤΔ Fraternity Letters - April 2025

Overview

This project involved designing, building and painting 48" tall ΔΤΔ letters for chapter events, tailgates, recruitment, and general signage. The goal of this project was to build large, visually appealing, weather-resistant signs, while spending less than $100.

48" is the size I opted for, as its the biggest size we could cut out of 4' by 4' plywood. While I could've used scraps to increase letter size, this would've required brackets of some sort, and added complexity. Thus, I stuck with just a 48" size. For wood, I used 3/4" MDF, as it was sturdy, and the cheapest 4' x 4' wood avaioable at Home Depot.

I used a photo I found online as a guide to mark out the ΔΤΔ letters. The Deltas were easy, and just required two lines form the bottom edges that meet at the middle of the tiop edge. I opted to make the "bodies" of the Delta letters 8" wide. I then visually compared the ratios of the letters online, and used those same ratios in my outline drawings. That way, my scaled serifs would still look good. I used a straightedge and a pencil compass when marking to keep everything as close to perfect as possible.

I cut the Deltas using a tablesaw, as that allowed for quick and easy, very straight cuts. The Tau required a jigsaw, as it had many curved sections that the tablesaw wouldn't be able to cut. For straight sections, I clamped a level to the MDF to guide the jigsaw. For curved sections, I carefully guided the jisaw along, keeping it dead on the line. Overall, the cutting process went smoothly, partially due to my good prep.

For paint, I opted to use Behr premuim outdoor paint, in Royal Purple and Brilliant White. These colors fit the ΔΤΔ colors the best. I used a basic KILZ Primer to prime the boards, and I used materials from the ITLL to facilitate the painting process. I opted for purple letters, with 1.5" while outlines. The letters got 3 coats of primer on each side, 3 coats of purple base, and 2 coats of white outline. I finished the signs with a can of Rustoleum satin clearcoat, to keep the signs weather resistant. While I only primed the back of the letters, I did use cleacoat on the back, to keep the letters completely sealed.

Overall, I'm very happy with how the letters turned out, and I can't wait to see them hung up at the house.

Process

• Planning: Measured available MDF sheets and laid out full-scale designs using a projector and pencil.
• Cutting: Rough cuts made with a table saw to manage large pieces; detailed shapes cut using a jigsaw.
• Sanding: All edges sanded smooth using an orbital sander followed by hand sanding for detail work.
• Painting: Each letter was primed and then painted using three coats of exterior paint — a purple base color and a white accent color for outlining.
• Sealing: Finished letters were sealed with a protective clear coat to withstand outdoor use.

What I Learned

• Selecting materials that meet durability requirements while also meeting a set budget
• Identifying ideal tools for specific tasks like cutting curves
• How to prep and paint for best finish and superb weather resistance