What material to use to make a 1:1 replicator?

[Sulla]

So I made a mock-up. Now I want to graduate to a sturdy, finished piece. What should I use to make this thing?

I want to put some kind of light behind the LCARS across the top to back light them so I'd like to make it sturdy enough to hold a light box with a small florescent light, as well as framed plexi for those graphics.

My first thought was Styrene. I could order two or three large sheets from plastruct and reinforce the walls from the outside to prevent sagging. Is there better material for this?

I'd love to keep my costs on material to $30 or less if possible. I also want it to be easy to work with. I know sheet metal would be great, but I just don't have the tools (benders, cutters spot welder, etc) to do a good job with it. I am great with plastics though...

What do you think?

Here is the cardboard mock-up I put together. It was inspired by the Defiant replicators.

 

[Sulla]

If I do go with Styrene, should I go with anything thicker than say, .125"?

And where can I get larg sheets fo styrene? Does Plastruct actually sell styrene in sheets larger than the hobby size?

 

[jackdoud]

And where can I get larg sheets fo styrene? Does Plastruct actually sell styrene in sheets larger than the hobby size?

Either check your local phonebook for Plastic, Plastics, or Plastic Supply or else google Plastic Supply and your state to find a local distributor.

 

[Gigatron]

To heck with styrene, I'd gut a busted microwave and use that :cool

But barring that, I have heard that places like plastruct sell large sheets of styrene (something like 3'x6' - or larger). Though I could only imagine what the shipping on that would be...

-Fred