Hi, Russ,
The Compound Cut nameplates pattern by John Polhemus uses the same principle you spoke of when you said, "Using the Keychain Pattern Maker you would have to create the first pattern, hit enter and create the second one on the same piece of paper. Then cut them out and glue to the top and side of the blank you are using, following along the directions/video for the 3D Key Chain Racer pattern." The names he used were Lucy Parks (4 letters and 5 letters) and Jemmott Harris (7 letters and 6 letters respectively) and there is also the difference in the width of the letters if you compare the letter 'M' and the letter 'I'. They do not have to be the same length. They are just centered on the length of wood stock without regard to how they align with the first name and the last name.
The font used for Mr. Polhemus' pattern is UMBRA but, I do not know what size font. He can call this a pattern because the letters are centered in 1 1/2" x 1 1/2" squares to be taped to your stock.
Steve's keychain pattern maker suggests using font size 105 to 120 BUT, that is a different font so
you would have to adjust for the font you are using when you type out your names if you are just using Word Pad or something similar.
Sorry this was so long winded but, I wanted to be accurate and detailed.
God Bless! Spirithorse