It's Done!
In March, 2012, I started thinking about making the map again, but this time making it permanent - framing it.
In October, 2012, I worked on the design. It would have:
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2 panes of glass, viewable on both sides
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about 24,000 pennies, 6 layers thick
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acrylic disks, the same size as pennies, to hold the pennies within the frame
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still no glue - the pennies will be held in place by the acrylic and the glass, and the acrylic and glass by the frame
I started building it on November 4th, 2012, and finished on September 11th, 2014.
It took 875 hours, spread over 22 months. (same as working full time, 40 hours a week, for 5 months.)
It has 24,204 pennies, 4,179 acrylic disks, and it weighs 554 pounds.
Here's a close-up of one of the joints in the frame.
And a close-up of Minnesota.