Hi,
I have a few originals that are pretty badly scratched and gouged, but I also have some fairly convincing faux badges that I make for my own equipment.
My faux sunn badges are the type you need, but I've intentionally omitted the "R" registration mark so that no one would confuse them with original parts.
The badges are bare aluminum, and the black areas are done with black vinyl. I use #600 wet-or-dry (used wet) to kill the gloss on the vinyl, and the finished parts look very nice from a foot or two away.
My vinyl guy charges me $3 each for the cuttings, and I have an out-of-state fabricator buddy who cuts the aluminum for me. I don't have a large supply, but I don't see why I couldn't make as many as anyone would want or need. It takes roughly 30 minutes to clean and sand the aluminum, apply the graphic and wet-sand the vinyl. I'm guessing that $10 each would cover it, shipping to the lower 48 included.
I made a few of these for HRobert, who I'm sure will give you an honest evaluation of the positives and negatives. Please note that Rob was expecting the smaller pieces; my badges are exactly the same size as the silver and black originals with the R mark. Mine are correct, but they are taller than the ones Rob needed.
Please remember that these parts are not meant to dupe anyone into thinking they are originals; they are made with the intent of fooling no one but myself. I will also include four black #4 x 5/8" Phillips-head wood screws with each badge.
Regards...
