Have a local graphic design/printer/sign making place print out stencils for the letters.

You can take close up photos of the letters, take measurements, and the printer can size them on the computer.

1950 Chevrolet 3100 (Ol' Roy)

1939 Packard Standard Eight Coupe (The Phantom) | 1956 Cadillac Coupe de Ville (The Bismarck) | 1964 Ford Galaxie 500 coupe |1966 Ford Mustang (Little Red) | 1969 Pontiac GTO (The Dishpit) I 1979 Ford F-100 | 1976 Ford F-150 (Big Red) | 1995 Ford F-150 (Newt)