The parts were designed to match the originals, but with slightly larger numbers. Since there was one additional letter in the last name, they do hang over the side of the holder slightly. One of my next projects will be to machine a new holder that fits better, and uses active caption instead of friction to hold them in place.
The letters will eventually be highlighted with black or blue paint to make them more visible from long distances
The letters were all machined from a single plate on a Tormach PCNC 1100, using a 1/8" endmill.
The aluminum plate was held down to a larger aluminum block with bolts. This allowed machining all the way to the edges of the plate. This block was later re-used for multiple other projects that required plate stock.