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I was thinking deeper profile initially, sprayed (cured whatever), the top of the profile machined off, then polished. Something like that would be the least manual work and most consistent result. Not sure about the machining, way outside my area of expertise!
@SideshowBob this badge looked pretty cool just polished brass. I made a few slips masking though so cut some lines into it 😑 No turning back at that point. FYI for anyone else, you just need light pressure with the knife!
veloham
@clubman might know how these were done. I think they were probably enamelled originally and he knows a thing or two about proper enamelling.
Application of the colour might have been done a bit like tampo, rolled on with a squeegee and maybe the excess scraped off if done by hand. Then oven cured which flows it out evenly on the surface. Polished up at the end. Just speculating though, I don’t actually know.
I’ve always felt that brass headbadges must have been quite an expensive item to put on a frame. First a set of stamps would have been made up to cut the shape out and then press the features into the badge, then the colouring, curing and polishing. It’s quite a lot of work!