For my first Instructable, I will be showing you how to make a backlit Star Trek Combadge wall decoration. My design is that used in Deep Space 9, Voyager, and the TNG movies.
For this build, you will need:
- 20" x 30" sheet of foam core
- A hot glue gun
- Plenty of hot glue
- A printer
- Flexible LED Strip. I used this one: http://www.amazon.com/gp/product/B00KAU4C40?psc=1&...
- Gold Paint
- Silver Paint
- Masking Tape
- A place to mount it
I have this in 4 Phases, the main part, the front detail, assembly, and the lighting. I have them organized like this because many steps, such as cutting and painting, repeat in multiple parts.
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Step 1: Phase 1: Template
You will need to print out the template. When you print, be sure that the entire thing is on the page. If you're using the default picture printer application in windows, make user "fit to page" is unchecked.
Once you've done that, cut the down and right facing margins off the top left part of the combadge.
Also cut the top and left margins off the bottom right part of the combadge.
After you've done that, lay the parts so the entire image is formed with all the pieces lined up correctly. It should look like mine.
Once you have it fully formed, put it on a sheet of foam board, aligned with the bottom edge, then tape the edges of the paper to the foam board.
Step 2: Phase 1: Cutting
Use a knife to score the outside shape of the combadge into the foam board. Also score the inside cutout parts.
Once you've scored it, take the template off, and continue cutting along the score lines.
Step 3: Phase 1: Painting
Mask off the side parts as seen in the picture above. Then, begin painting on the silver paint. Make sure that all of your strokes are in the same direction.
Continue putting more coats on until you're happy with your results.
Step 4: Phase 2: Cutting
Take the part of the template that was remaining when you cut out part one, and tape it to the foam board. Cut it out as you did with Phase 1.
Once you've done that, score out the rest of the raised part, then cut. Take out the middle piece, and discard it. Sand the inside.
Step 5: Phase 2: Painting
Paint the inside and top in gold.
Step 6: Phase 3: Glueing
Glue the top detail from Phase 2 onto the main part from Phase 1. Sand and cut the edges to match each other.
Step 7: Phase 3: Painting
Paint the sides of the combadge in gold, then continue putting on coats until you're satisfied.
Step 8: Phase 4: Construction
Before we can mount the lights, we need to make something to mount them to. I made 2 0.5"x10" strips and glued them running down both of the long ends. I then made 2 2" strips and 2 2.5" and put them on the sides. I also glued 2 more pieces between the bottoms of the long pieces. I'm unsure of the specific dimensions.
Step 9: Phase 4: Lighting
The first part is getting the wires in the adapter. Don't get discouraged if it takes a while. It took long for me.
Next, start gluing the strip onto the mounts that you made. I started with the larger of the two bottom parts. I also used hot glue in some areas where the glue on the strip wasn't sufficient. I also glued the adapter to the bottom of the point.
Step 10: Enjoy
Hang it up where you want it, and use the power cord to plug it in. Thank you for reading this and possibly making one of these for yourself. I hope it brings you enjoyment. Live long and prosper.