I have tried two options for painting a routed sign, but would like to hear a better approach. Would prefer to use sprays. One one lettered sign, I first painted the board, then covered with low tack masking tape when dry, then routed out the letters through the tape, then sprayed the letters, then removed the tape. Since the tape doesn't get cut smoothly by the router, this has drawbacks and requires a fair amount of touch-up.
On another sign, I routed the wood,sprayed the letters, planed off a thin layer to clean off the rest of the board, filled the letters with play-do, sprayed the board, removed the play-dough. It was hard to get the play-dough in, then it shrank and paint got between it and the wood.
Any suggestions for improving this process? I don't think I could paint these small letters by hand without a lot of overlaps.