GGPike, For me, having a large enough workspace is the idea way to go about this - it's the most important tool. If I start feeling clausterphobic, I'm screwed.
So here's my method and supplies needed.
1. Do this while my wife is not home.
2. Use a fold up table, with a hard plastic top to it that can get scratched up.
3. Get a few pieces of large foamcore, preferably ones that are not warped at all and have clean, pointy edges.
4. Use a long ruler, and draw whatever lines you want for cutting - straight lines are definitely the easiest.
5. Use a very sharp exacto blade - I used the box cutters where you can snap off a blade each time you make a long cut. I do this to keep the blade sharp, because a dull blade has a hard time cutting through foamcore cleanly.
6. Then use a hot glue gun to piece everything together.
I still have a lot of work to do on this, but will hopefully have one more update on it this week.
Thanks!