Shapeways Here We Come

The rear reflector is a bit cracked and in dodgy condition, and a new one can be very expensive, so I'm going a different route. I've drawn up a design in ViaCAD and I'm using ShapeWays.com to "print" pieces to build a new rear logo. I started by downloading the Porsche font and creating 3D letters. I added pegs to the backs of the letters so that they would fit exactly into a plastic plate that I would also print. The idea was that I would print stainless steel letters, a large plastic slab to mount them on, and a stainless steel frame to finish off the edges. Unfortunately, the original thick design of the letters would have been about $800 to print in stainless, so I brought them down to 2mm. The plastic slab would have been about $500, so I reduced it to a very thin layer that serves mostly as a stencil for the letter holes and also for the mounting points onto the car.

My plan is to print the letters, the frame, and the mounting "stencils". Then, I'll make the main plastic plate in a more traditional way (ie. not 3D printing it). Then, I'll wrap the plastic plate in something like carbon fiber, glue on the stencils, mount the letters and the frame, and mount it on the car.

I've ordered a sample letter in a couple of different materials. More later...