How can I engrave a logo on aluminum?

[Pastor Jedi]

done

I have an aluminum Klingon Bat'leth and I want to engrave the Klingon emblem on it. Any suggestions?

 

[jhusel]

You could make a stencil and sandblast it.

Jhusel

 

[roboprop]

I'd take it to an engraver. A bit more expensive (set up cost) but the end result will be much nicer than if done by hand.

 

[SmilingOtter]

I've etched some with PC board etchant, also known as ferric chloride. Might be a bit of a challenge with a big piece, but should be doable.

http://www.makersgallery.com/goss/etch.html

One caution - the reaction with aluminum puts out a LOT of heat and fumes. If you do it, do it outside.

 

[Hecubus114]

if your really want to do it yourself, a stencil and very slow dremeling has worked for me...