Intro

Many people have asked me how my projects BlackRage, FlameProof, and now Seraph's Pinion get their trademark etched look. The answer isn't a sandblaster or laser etcher, but a lot of patience, and 3-D etching with a Dremel. The idea itself is daunting, and will take a LOT more time than normal how-to guides, but the effect is one-off and certainly well worth the effort, especially at LANs, where eeryone is admiring everyone else's rig.

So with all this said, let's get down to brass tacks, say?

The Etching

To achieve this effect, which looks like a laser etching, I used Photoshopped templates, reversed to face right when I etched from the back side, and a Dremel to work them in. Always work from the back of the plexiglass! Even if you think it will be harder to etch it from behind (it is) the dirt and gook that he etching will pick up will NOT be worth it.

Here you can see our template, ready to be attached. It covers the whole are ato be etched, so you don't have to remove/reapply templates often. That lets you work longer at a stretch.

This shows the work to be etched, a Latin text in a PS font called Rage Italic, which is a standard in films for effects of this type. The mask is clearly backwards, because it's going to be etched backwards.

This pic, though a bit fuzzy (lack of ability to focus on something that small) shows just how small the bit I'm using is. I don't remember the part number offhand, but it's the smallest bit that you can get normally. (If anyone knows the part/model # please let us know.) It's just the right size for the font (22 point, for those asking) and will allow us to move rapidly, which is key to not burning the plexi.

The template is scotch taped to the window, after being aligned, so it doesn't skate around while you're working. At this point,it's evident there is another carving in this area. The etching is going directly OVER this area, for a multilayered effect that you can't get with sandblasting.

At this point, we pick up the dremel, say a prayer, and set the speed to 3, if yours has numbers. It's approximately 15,000 RPM. At this speed, go rather swiftly to keep the bit from digging in too far, and take frequent breaks to keep the dremel or the work from overheating.

At the carving, the technique changes. Here, set the Dremel to 5 (35,000 RPM) for max power, and use a bit firmer pressure ONLY in the carved parts. You can work as fast as writing here, if you can get the hang of it, which will once again prevent burning. At this point, the air being exhausted will prevent the dremel from overheating, so work until your hands get tired.

This is what you'll end up with. Don't get in a hurry, one flaw means a new window. Practice beforehand, so you can get a feel for what it takes to do this properly.

And as to whether or not the text can be seen through the initial carving?

As you can see, it ghosts itself through, giving the illusion of multiple layers. All in one 1/16" sheet of plexiglass.

Hope you've had fun, and be careful with that dremel. Always wear eye protection, and I wear a bandanna to keep it out of my hair as well.

Now go try it and post your results!