First up, printing out the proper sized thing, and cutting pieces out of the foam.
Once all the layers were glued and each puzzle piece cut out, I got to work on the acrylic pieces. I was still debating a few different ways to do the glowy parts, as well as hide the battery, but after a wonderful chat with Beer Money Props, we came up with a couple simple, and useful, solutions.
Next, I heated up a section of the acrylic and bent it over a small pipe, curving a section and leaving two flat walls, to make the middle section. Originally I was just going to make that out of foam, and insert a panel of the acrylic on either side, but this was his suggestion which was not only easier, but worked perfectly.
Finally, I used a forstner bit to drill a hole in the back for the wires, as well as in the front for the barrels. For that I used a slightly larger bit, followed by a smaller bit, to give them a bit more detail.
So I did. :)
Those strips of blue are bits of painter's tape, to mask off the acrylic. That will make more sense later. I also taped off the inside of the half-tube bit, to make sure no paint got inside, as well as the battery connector. Then it was off to the Plasti Dip!
Once that set, I took all the tape off, including the strips on the half-tube section and the paper protecting the acrylic. The result?
Ahem. Sorry. :D
The paint masking on the inside of the discs worked exactly as planned: there, but not holding back the whole light. The strips shone through wonderfully. You can see it best when I turned down the light levels on the camera in the third shot.
Finally, time to tie it all together with the weathering!