Yet Another Daft Punk Coffee Table (5x5 LED Matrix)

Step 2: Build the Display

I used foam board, which was recycled from one of my kids' science fair projects. It is a sandwich of white paper with a foam core, 3/16" thick. The overall size is approximately of our project is approximately 10x10x2".  I cut the parts with a mat knife, and hot glued it together.

To make the grid, cut 8 identical 2x10" pieces.  Then cut 4 equally spaced slits into each one.  The slits should be 1" deep,  the same width as the foam board.  Interlock the pieces to create the 5x5 grid.

Next, cut a 10x10" piece of foam for the back.  Hot glue it to the 5x5 grid.

Cut 2 more 2x10" pieces to form the sides, and glue them on.

Finally, cut the 2 (10 3/8)x2" pieces for the top and bottom.  My foam was 3/16" thick, so I had to add 3/8" to the length to make them long enough to cover the sides.  Hot glue them on.

Note that in the photo below which includes the top & bottom & sides, the LED's are already installed and wired up.  This is because I didn't attach the top/bottom/sides until I was in the testing phase, but it's easier to deal with if you glue them on earlier in the process.