Are you gonna be painting the backsides and edges of the letters and the bottoms and sides of the panel ?? In my time doing this, paint to paint isn't a very strong bond. It might be better to leave these areas unpainted and do a little touch up when all the glue is dried. This way, your tolerance only needs to be a slight fraction.
Thanks Gino...usually I would paint the tops and edges of the letters before hand, but not the bottoms of the letters. So I'd rout the
sign panel and spray the entire thing (several coats) to finish it off in the color that the deepest area needs to be, and then hand paint my way up to the most top area. In doing this, the pockets that will accept the letters will be painted. In the few times I've done an auto inlay, I feel like I had programmed in a .015" tolerance, but it has been so long since I've done it, I wasn't sure---so I thought I'd reach out to get other suggestions. I realize that this is a tough thing to nail down exactly...rather have it a little loose (but not big gaps) as opposed to having to shave the return of the letters upon assembly because of them being to tight.
What do you think of the .015" tolerance...am I close?---thanks again.