I wish I had taken more pictures of the process. I may go back and redo these if I still can't get a hold of reproductions. I started by creating a vector graphic, tracing the outline and detail lines from a pic of a pair of badges. The images came out to about an inch high. I printed out various sizes but stuck with the original 1" height. I took 1mm plasticard and cut out a blank shape of the 2 badges. I then mixed up some epoxy-sculpt and covered the blank with a 2 - 3 mm layer of putty, trying to get it as flat and smooth as possible. Using the EGYPT banner as a guide, I placed a print of the vector image and using a pin in a pin vise, I proceeded to poke holes through the paper, into the putty, along the detail lines.
The key to the hole poking is to let the putty sit for about 30 - 45 minutes. The first badge was way too soft and sticky and I lost a ton putty, stuck to the back of the paper.
After transferring the detail lines, I used sculpting tools to create smooth lines and depth. If I had time, I'd put more putty in various layers to bring out the depth even more.