HAL is now fully operational on my office wall and everything is going extremely well.
For this build I used only the main panel, ring, housing files, as well as the grille file by mabbog (https://www.thingiverse.com/thing:2065805)
All parts were sanded accordingly and primed with Tamiya grey surface primer. The lens housing and grille were sprayed with Tamiya metallic black. After double coating the grille, I sprayed it with Tamiya titanium silver. Silver rub n' buff was applied to the lens ring.
I inserted a gloss black sticker to the inside of the housing to smooth out the inner surface area as well as to give that 'deep' look of the real fish-eye lens. A black plastic holder for the 5mm LED light was also glued through the centre hole (this had to be drilled out with an 8mm bit to provide the right width).
Two different acrylic baubles were used for the inner and outer lens. The smaller lens was a 30mm bauble that was dremeled at a slow speed to prevent melting the plastic, then sanded. The outer lens was a 70mm 'locket style' bauble where the outer plastic edge was sliced off using an X-acto knife, and then sanded. I also blackened the edges of the lenses using a Sharpie so that once glued to the housing, you cannot see a seam-line.
The LED was simply wired to a 9V battery on/off switch. (I may install speaker at a later date)
A brushed aluminium car wrap was applied to the main panel on the print down side and then curved over the edges. I applied light heat using a hairdryer to secure the wrap in place. An X-acto knife was used to cut around the inner circle.
Although the HAL 9000 decal (PDF) was included in the Concentrix build, I recreated my own using a screenshot of the original artwork found by Master Replicas and sharpened up the image colours and lettering in photoshop. I also recreated the Nikon fish-eye lens lettering so I could apply a personal serial number to the decal. These were both printed on gloss sticker paper on an inkjet printer.
2cm x 1.5cm wood was cut to size and sanded, then backed onto the printed parts with CA glue.
Finally an aluminium alloy bar was cut to size and glued in place with CA glue. I was going to screw the aluminium in place with bolt screws but decided that would be unnecessary, should the prop ever break away I will bolt screw at a later date.
Big thanks to the creators for enabling me to display this proudly on my wall!
These are the pieces of my build for anyone interested, or wanting to replicate any methods used here:
LED light - https://www.ebay.co.uk/itm/3-5-10mm-Ultra-Bright-Pre-Wired-Constant-Flashing-12v-LEDs-Prominent-Holders/141336194100?ssPageName=STRK%3AMEBIDX%3AIT&var=441886787927&_trksid=p2057872.m2749.l2649
9V SWITCH - https://www.ebay.co.uk/itm/9V-Volt-Enclosed-Enclosure-Battery-Box-Holder-With-ON-OFF-Switch-Wires-New-UK/143056129641?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649
Inner lens - https://www.ebay.co.uk/itm/Two-Part-Clear-Plastic-Fillable-Christmas-Bauble-Ornaments-30mm-200mm/292597149107?ssPageName=STRK%3AMEBIDX%3AIT&var=591402195121&_trksid=p2057872.m2749.l2649
Outer lens - https://www.ebay.co.uk/itm/Two-Part-Clear-Plastic-Flat-Locket-Style-Christmas-Bauble-Ornaments-60mm-120mm/302681287495?ssPageName=STRK%3AMEBIDX%3AIT&var=601538400481&_trksid=p2057872.m2749.l2649
Lens sticker - https://www.ebay.co.uk/itm/Gloss-Matt-Black-Stickers-Transfers-for-6-6-Inch-Tiles-5-10-25-50-Packs/131394217217?ssPageName=STRK%3AMEBIDX%3AIT&var=430736346971&_trksid=p2057872.m2749.l2649
Brushed aluminium vinyl wrap - https://www.ebay.co.uk/itm/Black-Brushed-Aluminium-Vinyl-Wrap-Car-Air-Bubble-Free-All-Sizes/321695790900?ssPageName=STRK%3AMEBIDX%3AIT&var=510597838282&_trksid=p2057872.m2749.l2649