I made the changes and printed the new plasma globe base again and it turned out a lot better. Not only I shortened it slightly, I added the bosses and holes for the DC power connector.

I had a few minor issues but I as able to sort them out with some filing. The 3D print was a little off so the power connector didn't sit flush against the side. Plus I made one of the bosses too big. I shaved it down a bit. I also had to shave the mounts on the PCB so it fits deeper in the housing. Not much but it made the top cover fit tighter.

One nice feature I added was the two side extrusions on the top that pushed the PCB flat on the mounts in the bottom housing. That way I didn't need extra screws to hold it down. I did much the same with the power connector. So in the end I used only two screws, which I recycled from the original base, to hold the whole thing together. I made a lip on the top section that fits under a channel I made along the "neck" opening on the base. Everything fits nice and snug as a bug in a rug.

By the way, this is for my dragon fursuit head. I wanted to recreate the glowing globe in my jaws as shown in my latest badge (see https://www.furaffinity.net/view/33849423/ ). The original base for the globe was too big and wide. I could cut it down and glue it back into a slimmer form but I decided just to 3D print a new base. I think it is turning out nicely so far.

I am thinking of releasing the 3D models once this is all said and done after debuting it at this year's ACFI if someone shows any interest. I don't think anyone does anything like this before and something different that the usual LEDs methinks. I love doing weird and wacky stuff, that's me indeed.