First we tried to find, like, Tupperware or some type of box that was the right size for our arduino and circuit board, but no such luck. So we decided on the measure for the box and went Pro Build in Madison to get the wood for out custom box. We used Masonite because of it was both sturdy and easy to change and paint. We also bought wood glue, and got a little Tupperware to be the extension of our reset button. I applies gesso to all the wood to make it easier to paint. we got very cheap wood cutting supplies from Shopko but it was still very difficult to make clean cuts. When I got the box just as the wood, it was very rough.
To clean up the edges I used tape around all of the edges and then put gesso over everything very thickly so the that it would be hard to tell where the tape was and have smoother edges.
At first I was planning to paint it all black with red and blue lines to emulate the lines on the design, but instead I really like a dark blue and black texture.
I tried a couple more complex designs on the button--at first I was going to draw the two head-- and then just one head and it really just ended up looking better and just oh-so-press-able if I left it more simple and just wanted it to feel like a button. I wanted to to look a bit like the top piece of the rock-em-sock-em robot head--and incorporated the little circles like on the robots.
I was really happy with the box after I was done with it, I wish I could have put it all together so that I could treat the top and back edges with the tape too to have it smooth and nice-looking.