The aluminum is pretty thick so I used a jigsaw to cut out the letters. I scribed them on the aluminum first then drilled a 1/4 inch hole in each letter. Make sure you leave material in each letter so the inside of the R O and D stay there. You have to take off the jigsaw blade, feed it into the hole and reattach. Then cut out each letter. Clean it up with a file and paint. I used 1/4, 3/8 and 1/2 inch drill bits to drill the different sized holes in the other areas.