Step 3: Marking Up Your Ears
Here comes one of the hardest parts and time consuming parts. AS you will have to follow this step twice!
Grab some thick card and draw out a mock version of your ears.
Make up a few different versions, lining it up on the globe until you are happy with the layout of the ears.
This i found was the best way to make sure the ears where not too big or not too small and also sat right on the globe.
When you are happy with mock version, markout and cutout your rod slots.
This is best done by placing your rod on the mock cutout, and then drawing around it at angels.
Make sure you add an extra 2mm around each side so that the slots are just a bit bigger then the rod itself
When this is done cutout the rod slots you have just marked on your mock.
You should now be left with a ear template made of card with ear slots all cut out.
Now take your mock ear and write A on one side and B on the other.
(This makes it perfect for when we sandwinch the ears together with the rods in.
Place your mock cutout ontop of your foam board and draw around side A. Take your 2nd sheet and flip your mock version over and mark down side B. Take yours dremel and trim the foam board to size. Now you should have a complete cutout of your final ear.
Take a stanly knife and a ruler and now cut out the rod lines.
Now i stress not to push to hard only cut the paper layer on top.
When you have done that take a screw driver and slowly pickout the rod lines. Line up your rod and see if it fits nice and snug.
Follow this step above another time so you have cut 4 sheets of foam board and have 1 set of ears with all the rod holes cut.
Take your rod and now cut it with your dremel tool, my rods where 6 inchs long. And secure them in with hot glue.
Make sure you leave 1 inch of rod sticking out at the bottom. This is so you can attach your wingnuts!
When your rods are all cut and you have stuck them in, its time to take your fabric glue and spray the ears.
Now sandwinch the two A & B sides together thus creating a ear