Mario Question Block

Experimenting with thin metal lately I had an idea for my particular take on materializing a Mario Bros. video game [?] block.

Warning: Once you reach the "I'm researching pegs and a piercing saws" stage, there may be no going back.

Materials

• Wood block, 2" × 2"
• Brass sheet, 0.032"
• Copper sheet, 0.016"
• Spraypaint, Black, Tamiya (TS-14)
• Piercing/Jeweler's saw (with blades (0/5, 0/2), beeswax
• Bench Pin (peg), V-slot with clamp
• Wood screws, Brass Robertson #6 pan head
• Metal Etching (electro-chemical): white vinegar + salt, cotton ball, 12volt/5amp DC, leads, alligator clips, Vinyl (Removable, White — EasyPSV by Siser)
• Rotary tool, Milwaulkee (12v cordless, Dremel compatible), stone grinder, sanding stone, sanding mop, round carbide engraving bur
• Drill, Makita (18v cordless), 1/8" twist bit, 3/4" spade bit
• Metal Ruler
• Utility and Exacto Knives
• Cutting mat
• Clamps
• Rubbing alcohol
• Vinyl electrical tape, Masking tape
• Sandpaper (150, 220, 600 grit)
• E6000 adhesive

Process

• Sawed (hacksaw) brass 2" square faceplate, sanded (while taped on block to align edge and bevel).
• Sawed (piercing saw) copper question mark, sanded.
• Question mark shadow: Cut-outs in white vinyl (EasyPSV) w/ Exacto knife, masked brass faceplate. Etched with vinegar + salt + 12volt/5amp DC, cleaned and spray-painted black, sanded.
• 'Gold' Coin: Sawed (piercing) brass using a dime as a rough size, stone grinded, engraved slot with rotary tool witth round carbide bur, sanded.
• Block cavity: Drilled (3/4" spade), rotary tool with sanding mop to clean out.
• Spray painted block black.
• Drilled 4 screw pilot holes (1/8") (while faceplate taped to block).
• Put coin inside block, fastened plate to block with screws.
• Applied E6000 glue to back of each part of copper question mark, aligned next to shadow, clamped, let set overnight.

Conclusion

It was fun, would recommend. This was my first craft using a combination of wood, copper, and brass.