Step 1: Decide on a Design
You can easily import an image into a drawing program and use it to base your template from. For those that have skill in the " @4"<90" world (AutoCAD joke), you can draw your logo on top of the "research Image", and soon be on your way to the next step.
Step 2: Print / Cut
Now is as good a time as any to inform you that at no place in this Instructable, nor any other I intend to publish will there be a step titled: " Hurt yourself, or break something, as a result of being careless or too ambitious". that being said, don't do it. At the very least, try your best to be careful. After all, you can't enjoy creating a handmade project, if your hands are missing. :)
Now back to business. If your logo is the right size, Congratulations! you are doing alright. If not, Do not get discouraged. Simply try again until it's right.
All set? Great! Now cut out the pieces, and lets get cracking.
Step 3: Materials/ Tools
Metal cutting band saw
Angle Grinder with Flap disc
Welder and welder accessories
Blade ( for template trimming)
metal drill bit (that is same size as bolts used)
small magnets (for layout purposes)
1/4" steel plate
Bolts (whatever is available)
Clear coat enamel spray paint
Depending on the look your hoping to achieve, the thickness of your material will play a major role in the process. I chose 1/4" steel plate, because I wanted to bevel the edges and it still be on the clunky side( technical term). Most awesome things from the 80's were boxy and clunky, including alien robots. So, why should this logo be any different?
If your logo has duplicate pieces, it's good to label how many of each you will need. This will help you keep track of what needs to be cut out when you get to that step.
Step 4: CUT STEEL
Step 5: Grinding, Welding, And....flapping
Step 6: Prep the Bolts
I used a 1/8 inch thick metal ruler as a guide, and lined with permanent marker, the material I needed to remove to put the logo placement the desired distance off of the jeep surface. It's good to use a vice for this step, the bolts get really hot, and again it's safer to use both hands with power tools.
Step 7: Place the Bolts, Prep the Back
then, it would be clever of you to use a clear coat on the back to prevent rust.
After the enamel has dried, put some Silicone around the base of the bolts. this will help seal the holes you are about to make in your door.
Step 8: Placement
When you're ready to drill the hole, start with a center punch. It will be MUCH easier and more accurate.
Step 9: Mount, Season, and Seal.
Put some silicone on both sides of the bolt bits. logo side- silicone - door panel- silicone- nut.
I wanted my logo to look like it had some age to it, so I left it unpainted and let it rain on it a few times until the rust started looking cool, then I used more clear coat to seal it up. Now I have a rather permanent, rather tough, custom Autobot logo for my jeep. if you followed my instructable, and used the same design, you do to! congrats.