Basketball Jersey Lettering

[dietcokefiend.livejournal.com]

Have any of you guys done DIY basketball jersey lettering and have it come out looking clean? Someone wants me to make a dress out of that nylon or polyester athletic mesh and have some jersey-style lettering. I'm going to guess paint/ink is probably not the best option, and all the pre-made letters I've seen are either not the right color combination, size, style, etc. Think I can get away with using a different color mesh, fusing it to the dress, and doing a quasi satin-stitch around the edges? I have no idea how fusing would react with two layers of synthetic that have those tiny holes. Any input?