I’m making a “MERRY CHRISTMAS” sign for the yard. Letters are approximately 2 ft tall and will contain around 100 lights per letter. Used select grade poplar. Letters will be white with alternating red and green LED lights. Therein lies my main concern. The holes for the lights. See attached photos for reference. I made an “E” for test. I’m concerned the exposed wood in the holes for the lights to go in will expand/swell in the weather. (Kansas). Not only might it cause cosmetic/integrity issues but might actually crack the lights depending on how much it swells. However I’m not sure how to get paint into the holes adequately, if it’s even necessary or if I’m just hoping it’s not because I’m not excited about the approximate 1400 holes I’m looking at. Any help or advice would be much appreciated.
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