OK, it's been nuts behind the scenes, but I finally have time to show a full buildup of my 'final' version of this. Here we go. Apologies if I repost a photo or two that has been seen before.
First, let's kick off where we left it... METAL PARTS!
Overall really happy with how these turned out.
Test-fitting to a shell:
The laser took off maybe 0.3mm more than I thought it would, but it's fine. (The holes are not uneven... it's just he burn marks from the laser causing that illusion.)
Assembling the main popup arm. Making sure the plastic guide block slides freely.
Glueing the buide block to the aluminum arm:
Trimming the thin steel plates.
Time for some paint!
I gave the shell a black base coat (to stop any light bleed-through), then hit it with a bright metallic. Some "liguid green stuff" takes care of any places that need smoothing.
Dark gunmetal on the back plates, then decals, then a satin clear coat.
More to come!