The first attempt I made for a SS badge was by cutting a "S" from a SS tube. I started with drilling a series of holes then opened them up. This was very slow and I still had to file/grind a lot so I next used a jewel's saw. The follow up with files and Dremel took much less time. Here's a shot of the hole drilling step. It was the time it took to do this that motivated me to design a "S" on Emachine.com and seek a quote. I have been very happy with the pre made badges. Andy.