Awesome Rick! I've been hoping this would bring you out of hiding. :lol I would LOVE to work with you at some point. (forgive my shameless job begging)
Now that I know the actual size I want to change mine again! I started at 11" dia, then had to increase the overall thickness, and that made it become almost 13". I know exactly what your talking about with 10 pounds in a 1 pound bag. The original tricorders for next gen were like that. When I worked on trek stuff it was always like that, complex lighting rigs inside props less than the size of your hand.
The whole reason I went with the vacuform was because I knew I would have to do some fancy electronics hidden inside a very small cavity. I'm actually going to do the "blades" as soft rubber with LED's embedded so I can throw it and bounce off things and still get the lighting to work inside safely. Man, I wish I had the time to finish the electronics on this thing right now.
Rick, thanks for taking the time to speak, I also know of the pains of NDA's and how they can be so frustrating when you just want to show something to someone. Keep up the great work man, you inspire many with the countless hours of hard work you do. I hope they pay you well man, The Disney I worked with years ago was the most demanding people to work for.