Dan,
I went a slightly different route, though gotta agree with you that "Nemo"'s work sure does look nice!
Not sure if you still have bare metal or have already painted the base coat, and the method I used may work with paint or powdercoating, so FWIW...
I was doing a panel upgrade and making overlays on the old panel skeleton, so I had 3 flat sheets of .090 AL to work with. After cutting, we had them powdercoated light gray, then had the letters laser etched by a woman that does trophy and award placards. She taped the area with blue masking tape, then cut the letters through the tape. We then masked off the rest of the panel, leaving the blue tape on and leaving only the letters exposed, and we used rattle can black for the letters. Same could be done with white letters on gray or dark panels. Pics:
Pros: Professional look, durable (letter paint is down in the etching, won't rub off).
Cons: Changes not easy. I'd either have to cover the current lettering with a placard overlay (similar material to the N# placard in the first photo) or cut new metal and do it over. I figure if I'm gonna change things its gonna be bigger stuff, ie, to add a Dynon EMS to the right side or similar, so it'll be new metal on that side. I've added a couple cbs to a drop-down subpanel (for the new EI, etc), so I've been able to avoid changes to the panel so far (1.5 yrs). But that's why I did three panel overlays (left, right and switches)...just in case! If your panel is one piece, more flexibility may be important, but this could still work.
A couple guys on the field are using the same guy I did, but are doing removable/replaceable placards to go over the powdercoated base. They are not done yet, so no pics to share. However, I'll bet a good trophy shop or engraver could use anodized AL in just about any color that would complement your panel color.
Good luck, and looking forward to seeing how it turns out (my guess is many of us will be jealous!!
)
Cheers,
Bob