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Creating a Spherical Stencil
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As fun as it'd be to figure that all out, I think it'd be pretty rough for the actual end result. If you can get a sheet of thin rubber (whoopee cushion?), you could cut out the stencil, stretch it over the sphere, and spray. Could also take one sphere and project the letter onto it (light through paper-cut stencil from overhead), and cut out a stencil into an actual sphere - then drop that sphere onto other spheres (obviously the thickness of the spheres and/or whether they're hollow would factor into this approach). Might not be worth going through [i]all[/i] of this approach if you only need one of each letter - could just use masking tape (etc.) with light-projected stencil instead.
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