The first step in creating the star is making a printable template to help shape the wood frame and plastic. After scaling and printing the template at the appropriate size I took a piece of 4.25" x 0.125" wood from the craft store and measured the distance needed for each side of the star. I did not actually bevel any of the joints when I was cutting them so forming the star required support to keep the pieces in place while gluing.

Placing the template down on the work surface I used supports to hold the two pieces of wood in place as shown in brown in the picture. With the two edges of the wood touching, glue was applied on either side of the joint. Then taking a thin piece of balsa I cut out a triangle to mend the two pieces together and glued that onto the star. The reason for using balsa is that once the star is firmly together I was able to easily sand the triangle down to match the contour of the star, shown circled in the image of the star.

Because of the construction method, I had to wait a few hours on each joint for the glue to dry before moving to the next joint.

Once the entire star was formed I use drywall spackle to cover the gaps where two pieces of wood met at the tips of the star.

I then glued in some small stoppers around the inside of the star to help seat the LED assembly in place when inserted, highlighted with a rectangle. I don't believe they are actually necessary as gravity does a job of holding the LED assembly in place.

Laying the assembled star down on top of the Lexan sheet, trace the shape of the star and cut out the star from the Lexan. After cutting the Lexan star, verify that it fits in the wood frame, and then apply 2 coats of white spray paint to one side of the Lexan and allow to dry for 24 hours. This allows the LEDs to be diffused as well as hide them from view.

To hide the cap between the Lexan star and the wood frame I used a small 0.25" strip of balsa wood and cut it to shape and "capped" the frame so that the balsa covered the gap.

Finally added a stick/dowel to help attach the star to the tree top.