My first material creation for primary was the lowercase and uppercase sandpaper letters. I used the patterns the Preschool Years books, using old-style posterboard (thick stuff!), sandpaper cut and mounted, and construction paper for the colored backgrounds. I was and am satisfied with the results - they were sturdy, but I would never do it that way again:
- construction paper fades over time
- the letters were too small for most of my daycare children - not enough movement of the whole arm
- the colors did not match the movable alphabets that were most readily attainable (colors reversed)
- the letters were mounted at the bottom of a tall card; rather than placed in the middle or to the side of a "wide" card (the child should have a place to lay his unused hand to hold the board down)
- they were print
- capital letters in sandpaper letters aren't really necessary
- I should have asked to visit the primary room at the school to see what they used.