I did some googling, and found the easiest way was to use three layers of material (plastic or card) simple cut out, sprayed, and stuck together.
I set out planning to trace some screen shots/web images, to make a template, however, along the way i stumbled accross, Matt Munson who had a wide range of templates free for personal use.
Update - Matt Munson commented on this Instructable with the news that he had been prompted to add the files to his site again.
You can access all the templates here - www.mattmunson.com/props/
Thank you Matt, for allowing access again, so everyone can make what is one of the best props out there.
I am not providing the templates here, as he explains that he had previous problems with people using the templates for professional gain.
So, here is how i did it.
- Some world famous, gmjboard (super dense thick strawboard/cardboard)
- Some thin plastic transparencies
- a household inkjet printer
- a good scalpel and stanley knife
- Some double sided tape
- a sharpie
- some silver spray paint
Step 1: Get cutting.
Print out some of the templates, or design your own if your feeling creative, Its very easy to draw a simple design.
Stick the paper templates down to your selected board, My suggestions are to use either card, or plastiboard/styrene, both these can be cut using the stanley knife. Though the card is a much easier material to work with, it does give a slightly more rough finish.
Take your time with the cutting, many strokes, and less pressure is the way to go.
The corners are most difficult, but i found if i used the scalpel, and slowly nipped away around the corner it gave a cleaner better cut.