hi Jason, I posted up in the portfolio our new sign. It is clear acrylic that is lit and blocked out with black vinyl. It’s a good job and heavy, but you got to watch the join between the panels and how well your fuse the letters together with the back acrylic. We use Dicroypholine or however you spell it, its a chemical in a large glass jar.
On the inside of the box I would use small strips of clear acrylic glued to the back of the letter then to the edge of the box to hold letters in place.
Another way is to use composite board, machine the letters out completely leaving nice letter shaped holes. . then machine 10mm opal letters with a 3mm shoulder / lip on the back, these letters are then pushed through from the rear of the panel to plug the holes. . if machined right they should be nice and snug. . I tiny bit of silicon will prevent them from falling out.
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