Green Death Brainwashing Earphones

[elkad]

I used a 3 or 3 1/2" hole saw, (I have to check to see what size hole saw I used), to make the acrylic ends for the earphones. TIP: when cutting acrylic, cut slowly, use alot of WD40 oil, & cover everything around the drill press because everything will be covered in brown acrylic snow.
(Cutting was very loud & I had to wait til my mother was out to finish. She has sensitive hearing. She can hear a fly crawling on the other side of the house sensitive.)



It took two blocks of acrylic to make each end. I thought I could squeeze the two sides, cut in one block. Oh well.

[elkad]

I was thinking of using these mayonnaise lids to twist the acrylic off for maintenance.



To make sure I had a level acrylic I put together something to hold the acrylic & my drimel.



That made scratches which I had to hand sand. (I should have used the sanding tool insted of a cutting one.)



I just found out the acrylic is thicker than the light. That makes me think. Did the prop have a sunk in light to fit or was it flat on the top & sunk in the back for the nut? What do you think with this test block?

[elkad]

I used a piece of scrap wood to work out making the sink hole for the lights. The first hole is all ready cut in the acrylic.
I made a campus drawn stencil to keep both holes lined up. I found you can't cut these holes freehand or the light bolt & nut wont fit level.



What looks more accredit, the light on the top of the acrylic, or sunk in the acrylic?

[KIT-KAT]

I think it looks better on top 

[elkad]

I think it looks better on top  

Looking back at the reference images, the lights were sunk in & gave the acrylic a green glow. So, I think I go with the sunk in type.

[elkad]

I cut the neck off a couple Mayonnaise jars & glued them to the phones, then I glued the lids to the acrylic.



I labeled the inside of the cap & neck. Both lid necks were a bit uneven when I cut them to fit.



It.... looks... close....



Time to make the outer brace.



I should have given it more space. I cut 19", ended up with 17". I should have cut 20". More mistake room.



What do you think of the angels. More rounding on the top? Maybe a little smaller headphone pipes?



Lets paint these & go to the electronic & decorative pieces on the top.



I cut sum slits in the brace & bent the tabs to fit in the earphone jack.



The blue spacer circle is giving me trouble. Since I couldn't find any pics of the headphones on it's side & didn't know it the spacer was bent, a different shape, or maybe it was just a cut piece glued on.



Where do I put the acrylic arches? On, or against the brace?



The jack was scraping against the bolt, meaning I wasn't going to get the nut on. I looked back at the references & seen the jack was flush against the brace. So I drilled another hole & slid the blue spacer up. (I know its not blue, yet, but that's what I'm calling it for now.) I'm going to have to make another blue spacer with a longer back plate.

[elkad]

Cut a hole for the wire, tape it all down, & put the second layer over the wire.



Now for the acrylic arches. I used a hole saw & drill press. I marked both inner & outer part of the disk with the saw, then cut the inner out. Then I lined up the outer mark with the saw & cut it out. Cut the disk in half then sand. I made two encase I messed up the first.



Now the little acrylic block under the. Am I forgetting any marking detail on the block?

[elkad]

Done: http://tardisbuilders.com/index.php?topic=9805.msg119762#msg119762