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3D Printed and chromed custom hatch badging
So... recently I quit and leading up to my last days I've been trying to punch out the last of a few projects I've been not-so-successfully multitasking. And here begins the story...
Ages and ages ago I thought about replacing the 'GTI' badge with an 'R' badge - or adding it to make 'GTI-R' or something. Just a subtle hint the Polo had 'something' else going on (I'm all about subtle). About that time a HSV (complete with '317KW' badging) challenged my partner with a run onto the M5 and lost... We both thought this was kind of amusing at the time so I settled on a '300HP' badge. The HP thing because it's... Euro-ish and because I figured it'd upset the Clio RS/Pug GTI owners etc. I wasn't sure at this point if I'd replace the GTI or stick it on the other side...
So step one. Get an impossible badge. I did some research, tracked down the VW font on the internet and fed it into SolidWorks. I extruded a badge shape and rounded the frontal plane to match the profiled GTI badge. Like this:
Then I sent the model to a Stratasys Connex printer in an ABS like plastic. I made two sets - another forum member who's helped me out a bit has the other set. Though he says he's going to paint them black!?
I was pretty excited at the time!
Next step - get them chromed to match the originals. IMO, black badging is a step to far in the subtle mods. So chrome was it. I'd committed to the idea and struggled to find someone to take something on so fiddly. I eventually found a guy n not just willing to help, but was thrilled with the idea of having a go. So, two express post envelopes and scary bill later I ended up with this!
This is actual chrome. The guys sanded the plastic super smooth (super fiddly!) and used a secret jungle juice primer, and then nickel plated the plastic, before more polish and then chromed. They clink when they touch each other and have considerably different weight to them. They are so shiny you could use them as a shaving mirror.
Next step, get it on the car. I wasn't sure if I wanted to use the full '300HP' or '300' as it might better balance the 'GTI'... so I tried both and used the full badging.
So fighting the world's worst flu - I washed the hatch and gave it a quick polish. I agonised about 3M molding tape but did a little reading and figured Sikaflex would work. As it worked out it was a really good idea as it allowed a little bit of error. I very carefully spatulare-ed (sp?) about 1/8cc of sika onto each letter and measured it out with a tape and ruler. I put them on in their measured position - sat a few feet back and eye balled them in the last mm and degree.
They were taped into position overnight. The resultant bond feels very strong but has a tiny amount of elastic give. Just like OEM. I pushed the car out on the driveway this morning - first blue sky in a fortnight - and took a quick photo.
The car isn't a garage queen by any measure. So with the oncoming rain forecast for the week I couldn't bring myself to wash it. That and I'm still suffering from the flu. Thoughts? I was aiming for 'so-stock-you-wouldn't-no-any-better' I think I got there.
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