After millions of questions and pre-planning I'm finally getting started on my HIC. I am going to build a wooden box with 1x2s so it's a little lighter, and some thin pvc tubing for the rounded edges. I'm going to build the box 1/4" shorter than the blueprint to compensate for the 1/8" Sintra I am cementing and screwing on top of the wood. After it's all built I'll spray Han with some Pactra Indy Silver spraypaint and then Rub N Buff the Sintra for a metallic look. I took Friday off and I'll be building this thing all weekend, so expect a lot more posts and pictures soon. Thanks again to everyone here at DH and the HIC Builders Club, especially miqt and Stormrider, who helped me out and answered all of my questions. Just getting started but lots more to come after this weekend.
I cut the extra rubber around the edges of Han with a pair of scissors
making sure that the measurements matched up as close as possible
with the blueprint.
Then I cut the 5 pieces of Sintra with a Stanley utility knife according to the dimensions of the blueprint.