I decided to attempt to build a mockup of the missile box and spent a good chunk of time yesterday trying to draw out a diagram of it.
First attempt was to try tracing some of the outline. First issue was the little emblems molded on to the covers was interfering with getting level. Out comes the chisel and shaved one off. Pretty confident I can replace that with some scratch styrene or shave off the other one and call it good.
So now I should be able to trace it out. Laid it down on some sheet styrene I'd acquired and started the process. However, because everything is tapered, and rounded, and humped over it's near impossible to get a clean trace. And using a ruler to clean it up only highlighted how inconsistent each trace was.
Put my thinking cap on at this point. Everything is tapered so it's not like building a bunch of rectangles and calling it good. I was trying to trace it because Measuring angles is a bit extreme.
Introduced a minor epiphany. Realized can measure the widths and heights and connect the dots. Out came the calipers and a few choice words as I only have two hands and the job at times needed three. Needless to say I did get a template drawn out.
The arrows are to tell me which side of the pencil line to cut on. That Pencil lead is about the thickness of the taper so cutting on the wrong side of the line will either make it too narrow or too wide. However, I can now scan, print and apply them to the styrene as templates. Small step forward.
I still need to figure out how to build the side walls of the box. Again, no simple lines. Time for more caliper work? Nope, had another epiphany. Scan the part. Flatbed scanners automatically record inches etc of the image. It turned out a lot better than I expected.
Armed with a good high res scan,open it in a photo editor with a ruler and grid line. Voila, virtual calipers and no need for an extra hand. Each square represents 1/100 of an inch.
I can use this to outline the sidewalls onto the image and I just realized I can print the template from here without ever having to measure anything. Just saved myself from counting lots of little squares.
This process is still time consuming, but not as much and more accurate and consistent than if I tried to do this all freehand.