Can I make my own stencil to etch into polished aluminum?

[spills]

I just got done polishing the upper plenum of my Stealth Ram intake, just think of it as a polished aluminum box. Im wanting to blast/etch in some letters and whatnot on the side of it, but Im wondering what to use to cut the stencil out if. Ive got my own font and everything, but I was wondering if I could use some thin (1/8" maybe" rubber and line the bottom with double sided tape and cut it out of that? This is a one time deal, and I dont want to invest in those high dollar stencil makers. Anyone have any input/advice before I butcher my first polish job?

[jrow]

spills,

Are you going to mechanically etch or chemically etch? Contact paper (self adhesive shelf paper) is one that came to mind. They also make a product that they use in the medical profession called Dysime. I know the spelling is wrong because I couldn't fine it doing a Google! Maybe a good drug store could help with that. Anyway it's about 3/32 inch thick and is adhesive on both sides. Kinda stiff but should work on a flat surface.

John

[spills]

Im going to mechanically etch via a media blaster with aluminum oxide. would contact paper be thick enough to withstand the blasting around the edges of the letters?

[jrow]

spills,

I don't know whether it would stand up to the abrasive or not. Easiest thing to do is try it on some scrap and see. You might even try doubling it! They make a vinyl material that would work, I'm not sure if it has an adhesive back though.

John

[FigureLLC]

visit a local shop that makes signs. they'll have vinyl in various thicknesses and they'll probably have some scrap they'd be willing to give you free, or just charge you a couple bucks for a foot or whatever.

[boxgods]

Actually, the sign shop will have a special vinyl made just for media blasting that is thicker and has a better/stronger adhesive. In the sign industry it is sometimes called "sand carving" or etching resist--typically resist is used rather then mask. They can even take your artwork or font and size it to whatever you want and cut it out for you and apply the application backing for a very reasonable price.