I used Copperplate Gothic font and the letters range from 300 down to 50 in size. I just printed them out and cut them from fabric that I had adhered vliesofix (wunder under) to. You will need to use the sharpest scissors you have for nice clean letters.
I already had the frame , so using disappearing pen I marked the frame size on the white fabric and then fiddled the letters into place . Then I just peeled off the vliesofix from the back of the letters and ironed it to the fabric.
To get it looking nice and white I put a layer of thin wadding (batting) under the white fabric before I put it into the frame.
I left the fabric little too big for the frame so that after I had the back on, the fabric stuck out and I could pull at it to stretch it a bit.
The Boo Boo- My letters were nice and crisp and just before I attempted to put it in the frame , I rolled a lint roller over it to clean up bits of fluff and stuff and of course it picked up the edges of the letters and fuzzed them a bit.
So if you ever pop in to my sewing room , remember:
DO NOT PANIC ITS OFTEN WORSE