Step 1: What You'll Need - Parts List
3 packages of "Locker" magnets for the magnetic bases of the chess men.
1 Toy Bingo set for the body of the larger pieces.
2 packages of assorted plastic gems for the heads of the chess men.
4 miniature plastic zebras or horses.
1 square shaped sandwich container.
1 metal baking tray.
Some of the other items I used I either had already or purchased from the hardware store:
1 tube of Testors modelling cement.
2 cans spray paint 1 light colour and 1 dark colour.
1 can spray acrylic clear coating.
1 tube Super Glue.
1 roll painter's masking tape.
1 metal ruler or straight edge.
1 piece medium to high grit sandpaper.
1 pair tin snips.
1 precision knife.
Step 2: The Pawns
Step 3: The Knights
Step 4: Rooks and Bishops
The Bishops were made by combining 2 egg shaped gems back to back and then sanding down a flat spot on the fatter end as a place to cement to the bases. Again 2 for white and 2 for black.
Step 5: Kings, Queens and Promoted Pawns
The 2 Queens are very similar to the Kings, I just used more queenish gems for them. As always I abraded the plastics so that they would adhere to the modelling cement.
I decided to make a special piece to represent the queened pawns. This saved me from having to make extra Knights, Bishops, Rooks, and Queens. Instead I made 4 unique pieces which look like taller or matured pawns.
Step 6: The Board - Cutting and Masking
I measured the inset that was on top of the green plastic container and copied the shape to the baking tray. Next I used a pair of tin snips to cut the shape out.
I covered the cutout with green painter's (masking) tape and divided the surface evenly into the 64 squares which make up the playing surface of a chessboard. I then cut along the divisions with a sharp knife and removed the squares which would be painted black. I had decided to make the colours of my board black and silver and since the baking tray was already a silver colour it saved me having to mask and paint the board twice (once for black paint and once for white paint).
Step 7: The Board - Painting and Mounting
To protect the painted squares of the playing surface from wear and tear I used a Krylon clear coat spray. Before I applied the clear coat I masked off the edges of the plastic lid with green painter's tape.