Cost: Approximately $15 (assuming you have some tools.)

Required Tools: Spray paint (preferably Dupli-Color brand in your choice of colors), Dupli-Color clear coat, 3" wide masking tape, X-acto knife, 12-pointed star (similar to a Torx socket), 1/2" socket wrench, mild cleaning solution, weak paint thinner, old newspapers, and some clean rags.

Time: About 2 hours total (including drying time!)

Notes:

I chose to paint my engine cover Cardinal Red with black lettering, hoping to match the Neuspeed sticker on my strut-tower brace and my red spark plug wires. I chose Dupli-Color paint since it is available in a wide variety of colors from common stores like Wal Mart & Parts America, but it also dried to the touch in about 15 minutes which is crucial for the letter painting.

Instructions:

1. Pull your spark plug wires out of the black engine covers. You should need to remove them completely, just make them movable so you can get the engine covers out.
2. I purchased the 12-point star tool from Parts America in a four pack. Unfortunately, the tools don't have any size markings on them so I can't tell you exactly which size to use. You'll need the 1/2" socket wrench to turn the star tool. Remove all of the star-bolts and remove the black engine covers first. DO NOT PRY ANYTHING! Everything is bolted together, you'll break something if you try to force it apart.
3. Once you have the cover removed, you'll have to clean it so the paint sticks. If you've spilled oil on the cover, you will most likely have to use a degreaser, followed by a weak soap (like baby shampoo). I'd also suggest you use a funnel next time you fill your car with oil since the painted cover will most likely stain!
4. Make sure your cover is completely dry before you start painting... use a lint-free towel if you are in a hurry. Lay out the newspapers in a well ventilated area (automotive paint really STINKS) apply your first coat of paint. DO NOT HURRY THROUGH THIS STEP! Take your time, don't try to get a solid color on your first spray. If you apply the paint too heavily, the paint will drip and it will begin the fill in the lettering. The paint will also be too thick, and may take longer to dry. It took several coats for me before the cover no longer looked pinkish/silver. Make sure you get paint in the hole where the oil cap goes.
5. Once you have the desired color, let the cover dry completely. I only waited about a 1/2 an hour, but the longer you wait, the better. Take the cover outside to expose it to some direct sunlight, that way you will be able to tell if you have any missing or thin spots in the paint.
6. Now for the difficult part: the lettering. Place a strip of the 3" masking tape over the VW symbol and over the lettering on the cover. Use your fingers and fingernails to push the tape into the recessed lettering as best you can. Then you can use the X-acto knife to cut away only the part of the letters that you want painted. This is another step in which you will want to take plenty of time to do it right.
7. Once the taping is complete, make sure the entire cover is covered with either tape or paper... be careful of over-spray Once again, apply light coats of paint to the lettering. If you apply to heavy of a coat of paint, the paint will seep under the tape. I held the spray can about 2-1/2 feet away and lightly misted the lettering.
8. Don't let the paint dry this time! Pull the masking tape off as soon as you have reached your desired color. Once again, be care so you don't get paint on the cover where it shouldn't be. You'll notice that the letter paint probably isn't as perfect as you'd like it to be, but that is okay. Get out a clean rag and some week mineral spirits and begin to lightly 'cleanup' the edges of the lettering. I was able to cleanup the black lettering paint without removing any of the red paint.
9. Let the cover dry before installing... it shouldn't take too long (less than an hour.) Reverse the first steps to put the cover back on.

Impressions:
Although this is some what of a time consuming modification, it is a relative cheap way to make your engine compartment 'look like a million bucks.' I've seen people try to use fingernail polish and other brush on paints, and I must say that the method I used looks the best.

Todd Taylor
'97 GTI VR6