Thanks!
I used 3" x 1/8" aluminum strip.. cut out the letters, and shaped them using my Dremel, many bits (I kept wearing them out!) and lots of time! Each letter took approximately 2-3 hours. 1 hour to cut the letters out, and 2ish to shape, sculpt, sand, sand, sand.. and polish.
I did it in Aluminum because I saw the badge on the back of a Porsche Cayenne and LOVED how classy and stylish it looked.