This is my window badge (5" diameter) sitting on a reprint of the template I used, you can see it isn't perfect
but without the template there for reference you would never know.
Since my in process pics were corrupt I will cover the steps I took.
- Print template and adhere it to aluminum with spray adhesive
- Rough cut with jig saw from 1/4" aluminum leaving tabs in the center to bolt the two wings together
- Used a combination of 1/8" carbide burr in Dremel and about 10 different files in various size and cuts
- Cut tabs off and finish the inner edge of the wings
Next cut/route the window to inlay the badge.
Still trying to decide on the finish. (paint, anodize, or polish) and thinking about putting a 3mm LED in the side of each wing.Edited by Re-Evolution - 9/7/13 at 5:43pm