Thank you! I love this prop too and have always wanted one. Yes the prop maker made the graphics on his computer from screen grabs. I think they turned out really nice.
We discovered the other battery box side is a mirror image of the one you can see in the scene. You get a very brief look of it when McCoy takes it off Chekov’s head just before it goes off screen. We also noticed the pivoting Klingon part because in the far shot, the Klingon part is flat and then in the following closeup, it is at an angle.
Here’s the pics you requested. It’s my pleasure to share them. I’m just glad to find other people that are as crazy about these props as I am! Haha!
Here you can see the wiring that goes up to the Klingon part.
I think the support section may have been 3D printed? The top hinge and part of the side ones appear to be plastic.
The back uses the actual piece from the model kit that’s supposed to go there. I’m quite certain that’s how the original looked as well. If you watch the Blu-ray, when Catherine Hicks hands Deforest the prop, it’s upside down and you can see the back and it’s this piece that’s on there.
Nice view of the bottom where you can see all the hinge workings and the power switch for the lights.
I like that he added the curved head pieces just like the original and the soft black felt. It actually fits quite comfortably on the forehead! I tried to use it to get rid of a headache but I had no luck! Haha!
As for the parts, I found the model kit on Ebay. They are still readily available and I only paid $8 for it. Maybe someone can mold some of these as the kits start to become harder to find? I’m not sure where the maker of this beautiful prop got the battery boxes but they must not be that difficult to find either. I think they’re still being made. The only part that really has to be fabricated is the hinges and the support area.