Shapeways Redux

I received my completed parts from Shapeways. After ordering a couple of test pieces in different materials, I settled on a polished white plastic. The letters look great and very "real". 

I also ordered three pieces that would make up the mounting system for the main plastic panel. Printing the whole panel would have been extremely expensive, and too large for the print process, so I printed 3 thin pieces that were sized to fit the printing constraints, and matched the mounting points of the real Porsche reflector. The these pieces also served as a template for the precise holes needed to mount each letter.

After I glued the printed "template" to the back of the plastic panel, I drilled out each hole with a drill press. 

 The resulting fit was perfect - each letter fits exactly in place. The panel also makes a perfect holder for spraying the letters. I'm likely going to go with a steel/aluminum finish. More about that later...