The finished props! Now, a few of the things I realized I should have done differently.
- Rough cut the red plastic a little closer, so I wouldn't be throwing so much hot plastic onto my forearms with the Dremel. Ouch!
- Wait until the plastic was fitted before final sanding on all pieces. The Dremel roughened up the edges of the brass plates, and had to be re-sanded to clean up.
- Use a finer bit on the Dremel to finish the edges of the plastic. It took some time to sand out the marks on the edges, and that reduced the size of the plastic slightly, so it's no longer the same size as the brass plate.
- The pop-rivets are a little too small. All I had on hand were these small ones and some rather huge ones. I thought the small ones would be close enough. Eh, not quite.
- The mesh is too fine. I sort of estimated from the photos that the openings were about .0625 inch, and that was the listed size of this mesh. Seeing it all together... it's a little off.
- Holding it in my hand, the overall size seems a little big compared to screen captures in similar poses. I know that two of the main characters in Farscape, Ben Browder (Crichton) and Anthony Simcoe (D'Argo) are 6' 1" (1.85 m) and 6' 5" (1.96 m), respectively. Some big guys, but I'm about 6' (1.83 m) myself. It probably should be more like 2.75 inches (7 cm) x 1.75 inches (4.45 cm).