Unless I got enough people interested that I could justify having somebody cut the letters on a CNC, it's not something that I'd want to do. This was a very tedious build. Soldering the LED segments is tedious, hand cutting the plexi then sanding & filing the hell out of it is tedious, gluing it & trimming the glue is tedious, etc.
If I could get the letters cut on CNC, I could design them from 1/4" plexi with a 1/8" rabbit all the way around so that they'd drop right into place, as well as a mild indentation for the red letters. I wouldn't have to deal with cutting them out, and the glue-up would be way easier too because I wouldn't need to worry about the plexi or the letters shifting when I clamped it. The only tedious part would be soldering the LED segments.
Even with all of that streamlined, it would probably end up being $300-400 per unit to justify it, which I doubt many people would consider.
In terms of a status update, I haven't done much, but I did hook a small segment up to a DC power supply to stress test it.
I've had it running for a couple days now at just a hair over 15V. The segments are warm to the touch, but not hot, and they seem to be holding up OK. Running the LEDs on the truck at around 14V should prove to be durable if this section is doing OK at 15v. I also connected the finished light to the power supply and measured about 1/2A of current draw. That's low enough that I may be able to tap into the DRL or parking lamp circuit without a relay. I'm going to have to investigate that.
Now that it's starting to warm up a bit, I'm hoping to get out there and check out the wiring for the headlights and see if I can figure out what connector & receptacle style the headlamps use so I can see if I can get a connector & receptacle to make my adapter harness from.