Rob,
You need to find the right machine. Most Addressograph machines emboss the letters backwards to create plates to go in an address printing machine - like most hospital ID cards. The letters are often also coined into the metal to be very fine like a typewriter key. The vin printer forms the metal without changing its thickness & the result is as you see it on a carrier vin plate. I am sure you are correct that in production the plates would be pre stamped with the standard information including the border.
To change the font size it appears that you would have to change all of the dies & likely reset the spacing somehow. It may be a case of changing the die holder as well.
The machine in my pictures does not work whether by accident or intentionally. It is something that should not fall into the hands of credit card fraud miscreants!
There are a number of companies offering to make plates but they require an old plate or a proof of ownership of the vehicle. Would it not be worth collectively contacting these people, perhaps through a lawyer, explaining the situation of most plates being missing & that there never was any form of MOT title document on a carrier. A notarised statement of ownership should then suffice to clear the plate maker of responsibility. Such a person may be more interested if he sees a sale for many sets of plates. A die to stamp the border would not be too difficult to make.
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