Time to build the case. I wasn't sure where to post this as it isn't strictly part of the ship build, but I thought I would share the experience with you.
I bought the 5mm acrylic from a UK company called plasticsheets.com. I did consider buying the sheets and cutting it myself, but -
a. I would have had to buy a different blade for my table saw because you need a special one for cutting acrylic sheet.
b. I would have had to buy a router to get the edges smooth after saw cutting, and
c. Something would have inevitably got scratched during the cutting process.
So after some careful measuring of the ship I ordered the pre-cut sheets and paid a couple of pounds per sheet for polished edges (see later) - total cost was £115. When the sheets arrived they were well packed, the box wrapped in yards of bubble wrap, sheets unmarked, well cut and the edge finish was good.
I started by building it upside down and firstly taped the edges of the three sides -
Time to glue it. I did quite a lot of reading on what to use and quickly ruled out mastic (messy and too long to dry) and CA glue (causes hazing of the acrylic) There is a good vid on Youtube which recommends this -
but they were only building small cases nowhere near the size of mine, but I need not have worried. This stuff has lots of warnings on use health-wise but I don't think it is any worse than, say, cellulose thinners. That said, proper precautions should be followed. I got it on Amazon for £22, £8 of which is shipping, I guess because it is hazardous? I also could not get less than a pint, so I suppose it will keep me going for quite a while yet. The adhesive is water thin and is applied with a syringe and fine needle and then travels into the joint by capillary action - hence the need for very well finished edges. It does not so much glue the mating faces as melt them and results in a very strong bond. I gave it a couple of hours to dry and then taped on the last side and laid it down to help the adhesive run into the mating edges better -
Then stand it the proper way up -
- and after an hour remove the masking tape - I like to get masking off as soon a possible as it has a habit of sticking really fast and leaving traces if left on too long.
I'm quite pleased with the end result which gives me the look I wanted and it is as solid as a rock. The finished case is (in centimeters) 90 wide x 64 high x 39 deep and it cost me £115 for the acrylic + £22 for the adhesive (I only used a fraction of it) + £7 for syringes/needles (I only used one of each) - that is a lot better than the £1,100 I was quoted for one the same size with a base.
If you are thinking of making your own case then give it a go - it is a lot easier than you may think!
Still pondering the base finish - stained wood? coloured? something else? We'll get there soon. Regards.