I haven't been following this thread and just popped in to check it out.  The
subject sounds very familiar in the sense that a friend of mine who is a CNC
machinest/programmer has been making several styles of emblems for the old
splits.  Styles including peace signs, sun bursts, and (my personal favorite)
'recycle emblems, you know the three arrows in a triangle.  All of his
emblems included in them the "VW" logo as well.  In the past they were
machined out of heavy aluminum plate and as a result were pretty pricey
($75-80).  He has since helped create a CNC controlled plasma cutter with a
'huge' table/capacity and is cutting emblems and many other things out of
more realistic sheet metal which keeps the cost down ($20 or so - I really am
not sure).  Please don't hold me responsible for any inaccuracies in his
pricing/availability.  I can't keep up with his ever-changing 'side work'
schedule.  Last I could tell, he puts in about 50 hours a week working on
stuff on top of his regular job!

Any way, in case anyone is interested, his name is Mark Chambers, he lives in
Prescott, AZ and his e-mail is cncvw@primenet.com.