OK, bumping with my progress so far. As Epileptic Squirrel posted in his other thread, he had his Glitch cog machined out of ABS plastic. he sent it to me to mold and make some casts, but as of yet the weather has been bad every time I've had access to my casting supplies. I'm hoping to mold it up sometime in the next couple of days, though. Unfortunately, the glass pocket watch lens I bought turned out to be a little bit too big. I'm currently trying to track down a new one that's 1 size down, which hopefully won't be too small.
I just placed an order for some 1 inch wide pumpkin orange vinyl tape, and picked up this really cool looking tape along with it in case I'd rather go with cool than SA. It's sort of lenticular, hard to explain, I'll post a picture when it gets here.
And instead of messing around with fiberglass resin and screwing up the body even more I decided to just cover the entire thing in styrene, so I did. I cut all the pieces to size, glued them on with some epoxy, trimmed them to size, and sanded them smooth. Now I just have to find a good way to bevel the edges cleanly without rounding them off at all and then I can prime and paint.
So the only thing I haven't figured out yet is how I'm going to attach the back plate of the watch I bought without permanently gluing it on, so that I can replace the battery, change the time, etc. It uses tiny eyeglass sized screws to attach to the existing watch back, do they make drill and tap sets that small? Or am I going to have to bore out a section of the back of my cog and glue in the back half of the original watch case? Any recommendations would be helpful.