Okay, I was inspired. I've been wondering ever since the 640XL came out whether or not it would be manageable in my hands. Thanks for posting this topic. It has literally made my day, and caused me to be as much of a time waster as apparently the OP was.
I decided to take on this project, except not quite to the extent the OP did with colored paper and wrap-around with the paper and such. Instead, I loaded up front and back images of the phone, scaled them to actual size, and printed. Then I cut them out along with some cardboard paper, glued together a couple of pieces of cardboard, and glued on the images for front and back. It actually came out to the correct size, including the thickness. This method may be easier for others to experiment with the size of it.
Only problem is, I can't get much of an idea about "weight" of the item. While I have a set of scales that will allow me to measure accurately by the gram, I haven't tried to "weight" the mock-up. I could pour sand or sugar into the grooves of the corrugated cardboard, and seal it with a hot glue gun and get the correct weight, but first I thought I'd play with it for a while and see how it's working size-wise for me.
Pics:
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Here are the top 10 observations about THIS phone.
#1: Definitely going to have to be exclusively for 2 handed use, at least for me. Or... hands free using Bluetooth and Cortana.
#2: While this screen is easy to read in bright daylight, it's pretty much impossible to see in a dark room.
#3: The flash is completely non-functional.
#4: The phone is SO light weight, I can't set it down outside if the wind is blowing, or it will blow away.
#5: Does not hold up getting wet.
#6: Bends quite easily and leaves creases even after trying to straighten it out. Not for pants pocket use.
#7: The screen doesn't so much "scratch" as it does "tear" or "rip".
#8: Fails to pair with my Bluetooth headset, and can't seem to get any sound from my wired ear buds.
#9: Extremely slow and unresponsive. I tapped on a tile on the start screen over an hour ago, and it still hasn't opened up the app.
#10: Can't seem to get it to connect to my Wi-Fi.