Make D'Nealian Sandpaper letters

 So...I have seen some wonderful handmade sandpaper letters out there check out these and these for example.
I first printed the template from here ...she has even reversed the letters, so all you need to do is print them off. She also did us the favor of placing them very frugally on two sheets of paper as to only use two sheets of sandpaper...cool.  I chose red sandpaper for all the letters - that I found at Canadian Tire by 3M because...I did not want to paint my boards (made of smooth - both sides - Masonite) red.  I did paint my vowels boards blue.  A typical Montessori Moveable Alphabet has blue vowels and red consonants - mine does so I wanted to to do the same scheme - though you most certainly can choose as you like.  I used a glue stick to place the template on the back of the sandpaper, and then cut them out.  I used an exacto blade to cut the centers of a...b...etc.

I then used wood glue with a small brush to glue the letters to the cards.  Then with a foam brush...I put on a coat of Mod Podge - basically a sealer.  This does two things...makes them wipeable and seals the sandpaper to keep the grains of sand from rubbing off. Now...the Podge does not brush well over a glossy painted surface so I just coated the letters on the blue board and used matt spray sealer to coat those.

Finished!!!  This project is very easy to do.  My husband made us the double compartment box. 
I will also make a set of cursive in the event that Xander is keen to learn. I would also put a water based clearcoat overtop - I found the mod podge to mark fairly easily on the sandpaper portion - scrapes go a milky colour.