So two developments on the font size conversation if you'll kindly indulge me in answering my own post. A friend over on Air Craft Resource Center commented in PM that stencils were typically 1" or 1/2" tall. I had already gotten myself an early Father's day present in the form of a digital Caliper and measured a plastic model kit. That measured just about the same in scale.
In practice, the font size is about 2.5pt. As for printing, that has yet to be tested. We'll see how my printer fairs on my next test.
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Happy Crafting - Scot
On the Bench: Planck and Hershcel
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