In addition to the wood structure, for casting i packed each letter in sand - i used fine casting plaster - all edges were sealed and, there were few leaks
an obvious problem is the dampness from both the plaster and the sand soaked into the card and buckled some of the straight edges - notable the letter U - next time it would be a good idea to coat or spray varnish the card to waterproof it. Contrary to this the curved edges seem to have come out exactly as modelled
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