After creating all the letters I discovered Q and W both hung off the top of square bricks, so the letters are actually a bit smaller now. The stud modification worked to make the bricks easy to connect. There are a few more things I will attempt to add or adjust to get the printed bricks as child friendly and as functional as possible.
I also discovered a problem when attempting to connect more than one brick on the same set of studs, it could be slicer settings or nozzle size issue, but it may require refining some numbers.
Industrial 3D Printer Filament PLA