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I am an avid sewing FREAK! I am currently working on a quilt for a sister's wedding.
As for making letters, I must advise AGAINST using any type of paint or quick fixes for making letters unless you only plan on wearing them for a skit during rush or a campus stage show. My reasoning is it just looks cheap and home-made. The integrity of your fraternity deserves the standard heat and bond backing and a simple zig-zag stitch from your mother or grandmother's sewing machine. Furthermore, the paint and other stuff will crack, chip or fall apart within three washes I PROMISE!
So please, for the sake of your chapeter raise your right hand and repeat after me, "I [state your name] promise for the sake of my sisters I will not go astray and tack down MY FRATERNITY'S letters with any type of temporary hold including but not limited to, puff paint, slick paint, seam binding, braided cord, piping, or rick rack in an attempt to save money" AMEN
What I do is take a shirt that I like the lettering style of and make a photo copy of it. Then I cut out the shape and use that as my pattern. Then I go pick out two fabrics 1/4 yard is plenty. I get a solid and a print and a 1/4 yard of something called wonder under. Wal-Mart carries this in the fabric department. Cut out a small section of your printed fabric and iron this on your wonder under. Then, take your pattern and trace it on the paper backing and cut out the letters. So at this point you have two fraternity letters with wonder under on the back. Now take the solid fabric and cut off a small section (make sure it is bigger than the printed material because you will be ironing the printed material to the solid) and iron that on another piece of the wonder under. Don't peel off the paper from the solid yet. Okay, now iron the printed material on the solid peel the paper off the solid and zig-zag around the letters. Then cut out around the printed letters and place the double layer on the t-shirt and iron. Then repeat the zig-zag stitch and tie off your threads. It is easier than I make it sound.
Give this a shot and if you get stuck post your questions.
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