This is an interesting puzzle, but let’s bear in mind that the original was made. And it’s rarely within the purview (which is to say, budget) of movie prop departments to do things that are ridiculously hard or take forever, especially for a slightly incidental item like this (as opposed to, say, a model of the Enterprise).
I am mostly just looking for an accurate replica I can put on a shelf and maybe put some a sheet of blue lighting gel inside to make it look like it has ale inside. I’m sure that alcohol will probably degrade acrylic over time.
We could certainly machine a master in metal and then cast it in acrylic (though, given the geometry, a bonding point would still have to be made, probably with epoxy). However, I don’t think it will give the same visual effect. Those discrete layers of acrylic in the original, because it is clear, make the light play inside the object in a particular way that wouldn’t be replicated if we were to cast it solid. Perhaps we could cast the individual components and then bond them together, but I’m not sure that you can weld cast urethane like you can with acrylic.
Glass would be absolutely fantastic! I would happily pay hundreds of dollars to a glass artist to make one of these for me (or we could do a group expense share on here at cost). However, tight-tolerance glass is really hard to get made, from what I understand. There are smaller glass artists who can hand-blow stuff and so forth, but that wouldn’t really be suited to a project like this. I would love to be proved wrong on this though! Anybody know anyone with expertise in glass?
I am honestly thinking turned acrylic welded with solvent, like the originals, is the way to go.
Depending on how hard they are to make, I may end up just making one for myself, in which case I will of course also make one for you. However, if it’s not too difficult I’ll definitely try my best to make a few more. In my experience, hand turning parts can be very time-consuming, and I’m just concerned that acrylic in particular is going to be especially tricky.
However, if I work out the process and we create a good set of canonical instructions, maybe some others on here will make a few as well.