http://www.dafont.com/
Go through find a font you like follow the instructions to install it on your computer then open a word program and write what you want. then change the size of the font (you can highlight and type in a larger number into the size box) to however big you need it 600 is going to give you about a 5.5 inch letter, print it out and use your favorite method of applique! I have used font size in the 900s before which are HUGE!