I hope you don't mind me chipping in on yor thread with a few photos of my WIP. I spent a long time looking though the various wallets on ebay to find one with just the right curve on the corner, stitching and window size. I found one I liked the look of, but only the NYPD mini shield version was listed. This wasn't too bad, as it would allow me to cut my own aperture to fit the Gecko badge. After waiting almost 3 weeks for it to arrive (seriously ebay? how can a letter-sized airmail parcel take that long from the US to the UK?) it finally arrived today, so I could make a start..
After the initial look-over it looked promising on size, so I taped up the badge panel, marked the centre line and placed the badge over so I could trace the outline (the X marks around the edges of the badge make it easy to line up with the centreline). I then put a new blade in the scalpel and set to work:
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Sizing looks dead-on, and the badge is a nice snug fit. After the faux-suede flap had been removed it sunk in to almost level with the surface of the leather too. The next thing to look at was which phone backlight panel I need to go with - I had ones from an iPhone 5S and a 6s. The one in the picture is from the 5s, which looked like it would be the right one:
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Again, a near perfect fit. The only issue is that to get the screen, the support PCB/power supply and battery in there is going to be tight. On the real prop it looks like they solved that by sandwiching an extra strip of leather along the edges on the ID side to make the 'pocket' wider, so I might have to do the same (maybe using foam rather than leather, which would be tough to line up new stitching holes through). The other option would be to carefully hollow out the back of the badge to get the battery and boost converter behind it.