I did it once many years ago. I used a plastic template I got from Seyco. Kinda bubbly letters, 5/8". I used my dremel on a plunge router base to cut the center of the letters. I had several strips of wood ready (already cut 5/8" and sanded.) I had pine, cherry, red oak and walnut. The more expensive the wood, the more expensive the key chain. You want to have someone else there to help work your booth. You don't want to miss a good sale because you are working on a $5.00 key chain. You also want to have a few made up so they can see the finished results. I did OK on the key chains but got some special orders that made some real money. It's a good idea if you have the right venue.
