Gino: It is hard for me to fathom that you can make a set of channel letters cheaper than you can buy them (unless you are running a full-scale production business). By the time you add materials, burdened labor, overhead (specialized equipment like paint booths, exhaust and air replacement, automated brakes and notchers, routers, in addition to general overhead such as sales and office help, rent, heat etc.), most shops will be left in the dust when compared to wholesale suppliers. Big shops like Young Electric and Federal Heath can do this, but their production facilities are on par with (or even bigger than) the wholesale fabrication companies. Yes, a small shop can buy the equipment and train the operators, but you really need to be doing over 100 letters a day to cover the expense of even the most modest modern channel letter production line. If you are doing that, then congratulations, but I am quite certain most shops are not.