Flat-Bottom

Flat-Bottom letter molds are the most inexpensive for two reasons.

     First, they are simpler to make than the V-Bottom letter molds.  (It

can be a little tricky figuring out what angle of bevel will work on a V-

Bottom mold.)

     Second, they can often be made with thinner stock than the V-

Bottom letter molds.

In fact, with larger letters, sometimes a Flat-Bottom letter is required.

 The reason being that in order to create a V-Bottom the depth of the

letter may be too great.  For example, in the diagram on this page we

see a section of a letter that has a six inch wide stroke (letters 18" and

up can easily have segments this wide).

As you can see, if a V-Bottom letter was desired, the overall letter

depth would have to be close to 2" deep, (even with the lower-angle

bevel shown in the diagram).  This depth may not be acceptable as it

may weaken the structure.  Also, to get that depth in the V-Bottom

letter requires using thicker sheets of Duro-Tek, which adds

considerably to the cost.  On top of that, in order to cut a bevel that big

requires either a very large (scary) bit or muliple passes.  Either way it

means more expense.

So, since the Flat-Bottom letter molds are easier to make and can be

made with thinner sheets of Duro-Tek, they are often the least

expensive way to go.