I am doing a restoration on a STTNG and the head required repainting. Cabinet is in real nice shape but the head had the typical scrapes to the sides, top and bottom, (doorways I guess). I did a search on redoing the backbox warning. The best answer certainly seems to be silk screen (and also the quickest assuming you already have the supplies). Appears to be the way the factory did it. Unfortunately screens and supplies can be pretty expensive especially if you are only planning to use it once or twice. Most of the reports about trying to use stencils were pretty negative. I own a hobby grade vinyl cutter that I use to make graphics or cut the iron on covering for model airplanes, my other hobby. (reason for the avatar). I have also used it to cut stencils for painting on fiberglass portions of the aircraft with pretty good results.
After doing a search for the file, 2 pinside members came up swinks and Big_Bob both of whom sent me files to play with. Thanks guys.
I made a small section of the file to test it. I have 2 different spray mask materials one with a low tack and the other more normal tack. I experimented with both of them on both a rough surface (smooth ply sprayed black) and a smooth surface, primed and sanded ply sprayed black.
The first image are the masks applied to the wood. The white one on the left is the low tack and the clear bluish one the higher tack.
stencils-2000.jpg
I have to admit that my first attempt using rustoleum yellow didn't work. The paint was too elastic and tore off with the stencil
I then tried the same paint I use for my model airplanes a water based acrylic, Auto air colors. The only issue is that you have to spray a coat of white before the color. The paints are easy to use using a heat gun to dry each coat. Doesn't take long at all to apply.
stencils painted-2000.jpg
This is the result of the low tack stencil on the rough surface. Definitely some creep of the base coat white.
results 1-2000.jpg
The higher tack mask did OK on the rough ply.
results 2-2000.jpg
On the smoth surface results were similar although the mask affected the satin black base. Not sure if it was the paint or because it was only 24 hrs old.
results 3-2000.jpg
results 4-2000.jpg
Now I have to tell you that even painting this small area was a ridiculous amount of work to first weed the stencil, transfer it to the wood and then remove it after painting. Letters like A were a real pain in the ass.
Finally I tried using the cutter as it was intended. How about a vinyl lettered back box warning? I had white not yellow but you get the idea. Definitely the quickest of the non silk screen choices.
vinyl letters-2000.jpg
vinyl results-2000.jpg
Stuart