Step 1: Materials Needed
I had already used the original red/yellow cover of the case as the ground plane for a WiFi patch antenna (see two of the pictures below).
Scrap metal sheet
Pliers, rib joint pliers
Square angle ruler
Round shaped knick-knack
Template for Pacman, Paul ( and Steve and Matthew)
Sugar, flour, butter, eggs...you know for what.
Step 2: Flattening, Drawing, Marking, Cutting, Marking Again
Unfold the round edge right at the joint along the side of the box. The box will start to open quite easily. Do not force it. You need to remove the bottom cover. With the pliers unfold the round edge all along its perimeter. Be patient and work the edge a little at a time. The cover will come off easily and the box will open (not really much) flat. Make it flat watching out the sharp edges.
Step 3: Mark & Cut
The ruler you see in the picture I made out of an aluminum bar taken from a 19inch rack of an electrical control panel. The markings were done with Autocad and printed on regular A3 paper. Glue and transparent protective plastic made the rest.
Now, if haven't done already, wear your safety goggles.
It is time to be precise. With the scissors (a regular but pretty strong pair) cut the strip along the line.
With the ruler and square angle ruler mark the lines where you will bend the strip.
Step 4: More Cutting. Bending
Start bending using pliers, the book or anything you fell confortable with. Use the round knick knack to make, well... the round part.
Step 5: Add Some Features
Interlock the two sides of strip. Align, do the two small cuts and bend the joint to keep the joint from undoing. The last two pictures refer to Pacman rather than the Ghosts, but the principle is the same for both the caracters.
Step 6: Pacman With His Eye (did He Really Have One?) and You're Done.
Using some of the strip you cut make Pacman's eye with the aid of the pencil and pliers.
I do not post pictures of the biscuits I tried to do with these cutters because they went on fire.
Biscuits on fire, biscuits on fire !!!
Ciao e presto