Step 1: Planning
To save on the amount of caps I would need to complete the design, I decided to flatten them out with a hammer; carefully avoiding folding the sides over.
Step 2: Layout on Cardboard
Note: It took me 5 months to gather and flatten enough caps.
Step 3: Transfer to plywood
Once traced onto the plywood, I carefully cut it out with a jigsaw.
Step 4: Applying the Caps
Overall I used 3 tubes of silicon and 1/2 tube of construction adhesive.
Step 5: The Finished Product.
This was a really fun, albeit time consuming, project. 540 caps = 90 six packs = ~$7 per six pack (depending on the brand) = ~$630 worth of beer.
I've started collecting caps for my next project -- if you own a bar and want to help out, collect your caps and mail them to me. Or if you're local, I'll come out and pick them up!