Nose Badge Project II

5/7/08 - Getting up to speed on the new Haas CNC mill and decided to draw up a metal nose badge and see how accurate I could get using a 1/32" end mill.  Well five end mills later, I finally figured out the speeds and feeds and milled out my first prototype.  The lines were crisp and the aluminum was an easy material to cut, but traditional enameling wouldn't work as the firing would either distort or melt the metal.  The correct material would be guilding metal which is a copper and tin alloy, but I'm having problems locating .125" sheets.  I also noticed that I could get away with shallower pocketing for the enamel which should cut down the 3 hour milling time.  I'm thinking about milling down the back of the aluminum badge and welding on two studs.  Then I could use colored epoxy in place of the enamel and polish the aluminum.  Hmmmm...........