I really want this light to be as compact as possible, a 40mm version would have been perfect and I don’t think filing these things down is an option 
Maybe could use it for a future build.
The wood I ordered is only 55mm wide but still, I’ll give it some thought :+1:
Got the copper sheet cut into the rough shapes today.
I marked out the lines to cut with digital calipers, a set square and a #26 scalpel blade. I was not looking forward to cutting the metal with a hacksaw so I thought I would try just scoring it repeatedly with a stanley knife, about 20 times down the marked lines each side and then gently bending at the weakened points until the pieces snapped off, much easier :THUMBS-UP:
Each layer is about 1mm larger all round than required, to be made good and sanded down later.
Reference drawing
I also marked out where the glass, optic and MCPCB will be situated through the front piece using the digital calipers with one point held in the centre marking and the other point used to scribe the circles around.
These circles will help to keep me right when taking out this material with a hand file.
I will cut the rosewood next.
Today's Tune:
www.youtube.com/embed/4NIH__j3-vU
I love copper. How thick?
It’s 1.2mm thick, nice stuff.
Measured and cut the wood, now got the rough pieces made up.
Reference drawing
Looks nice but you don't want to eat this sandwich :-)
Today's Tune:
www.youtube.com/embed/EdPGpjdQuGQ
Looks like a high-end dessert. It could compliment the brass-burger I made yesterday 
More work on the wood today, this is quite difficult when all you have is metal working tools. Hats off to you cabinet makers out there :THUMBS-UP:
I marked out the rectangle shape to be removed with digital calipers fixed to 8.5mm for the long sides and 10mm for the top & bottoms as these still have work to be done on them. I drilled a series of holes inside the lines then used the drill bit(s) to go around connecting the 3mm holes. Snapped five bits doing this :TIRED:
I tidied the holes up with a file, might sand down further later.
Reference drawing
Rough pieces coming together :-)
Today's Tune:
www.youtube.com/embed/JY3znEOMzRQ
Ah yes…… time for the group buy! 
You have to love a good looking piece of wood. How big is the vice?
That one has 4” jaws and a maximum 4” opening, I have two small tabletop vices that I use, not fixed down to anything so that can be fun sometimes
It’s even harder working metal when all you have are wood working tools.
I like that wood. Looking nice.
That vice (with the orange button) looks like a twin to one of mine.
I can totally understand that
I thought about the wood for a while going between american walnut, ebony, rosewood and a couple of others but being honest I chose this piece because it was the closest cut to the dimensions I required
Yeah an ex got that vice for me at lidl about 7 years ago, best thing she ever bought me
Crx it is already looking awesome !!!
Thanks CRX. The reason I asked how big the vice was is to get an idea on how big your parts were.
Thanks mate 
Right , well looking at the lights parts from the front is about the same size as a credit card, 85mm x 54mm and maybe 20mm thick total.
More work on the rosewood, drilled 3mm holes for the red bottom LED's, charging indicator & top momentary switches and cut out a channel for the USB charging port with a junior hacksaw.
Had an idea to cover the back end of the auxiliary LED's with a mix of glow powder and resin.
The USB port I have taken from an old converter that I had.
Sanded down two momentary switches.
Marked out and drilled holes for wiring in the mid copper layer.
Bits n' pieces.
Reference drawing
Today's Tune:
www.youtube.com/embed/MnXMECZup2M
Cool! Looking good.
Sure is.
Someone has to ask , what kind of black magic is this ?
lol , good idea right there