During the winter while I was beginning my EFI conversion I made an intake plate. The stock t-bird types didn't look too special and I used a few stock ones as experiments.

The plate was screwed to a board and a standard router and bit was used to mill off the ford lettering. The bit cuts soft metals like aluminium and brass just fine, although it must shorten the bits life.
 Plywood the same height as the plate supported the router base at the right level to avoid gouges.
 The first plate was left blank, touched up, and painted.

 The next one was more ambitious. I had a real grill horse that I found bolted to the nose of a 79 mustang. Its' ford number is D4Z8-8216-AA.
 I also knew how to use molding compound, and so combined the 2 into a copy that would be added to an intake plate.
 The type used was from http://www.smooth-on.com/ . They have a wide variety of casting, molding, and special effects stuff.
 The mold was made from cardboard and glue. Some use legos.
 The horse was suspended above until the mold hardened. The bad thing about this method is that bubbles rise to the inside of the mold. Degassing would be a good idea. The finished 'rubber' is stretchy yet strong, and can be cut with a sharp blade.
 The copy is resin and some fiberglass to give the weak areas strength.

 It was epoxied to the plate and touched up. Unfortunately, after it was painted to match the intake some bubbles popped up along the seams. It looks pretty good as is, but I'll redo it after it really sets up.

Here it is finished. It was sprayed the same color as the manifold, and then the background was sanded. Black 'krackle' paint was then hand brushed in several thick coats.