On the home stretch now. After hours and hours of cutting cotton swabs with my finely crafted "height gauge" (the back of a business card) I can start plugging them into the grid holes.
I think I was able to watch an entire season of Myth Busters with the time it took to accomplish this.
Another noteworthy observation while completing the project is how heavy the it became. There is some serious weight to a crap load of cotton swabs.