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Dark smalek build
- 2. Contents • The Plans • The Dome • The Eyestalk • The Eyestalk Cowl • The Lights • The Skirt • The Bumper
- 3. The Plans-Project Dalek • Join Project Dalek online for nominal yearly fee • Allows access to the plans that have been created by other Dalek Builders. • Also allows access to forums where materials and techniques can be discussed with other members.
- 4. The Dome The plug, the mold and mother mold, and fiberglassing
- 5. The Plug-Materials • ½ in sandply plywood • Round or Octagonal wooden axis piece • 11 gauge galvanized wire • Masking tape • Heavy posterboard • Plaster of paris • Galvanized sheet metal • Plastic for template pivot
- 6. The Plug-Armature • Base • Ribs • Sweep
- 7. The Plug-Surfacing • Surfacing materials • Wire • Tape • Poster Board
- 8. Plug and Sweep Ready for Plaster
- 9. The Plug-Plastering Rough Base Coat After Cutting (Sweeping)
- 10. The Plug-Plastering Finished Finished Basic Shape Rough Basic Shape
- 11. The Plug-Detailing • Carve out details with custom made tools or possibly a Dremel Tool (With Burrs or wheels)
- 12. Correcting Plug Defects With Autobody Pinhole Putty Finished dome before correcting small defects
- 13. The Mold-Materials • Silicone Mold material and thickener • Plaster cast material • Bolts • Material for separators o Ex: Luan Plywood, Cardboard, etc. o Covered in Wax paper
- 14. The Mold-Print Coat • First coat of silicone--no thickener • Used to pick up fine details
- 15. The Mold-Building Up • Two coats of silicone with thickener • To make mold strong enough to remove without tearing
- 16. Keys added to silicone mold to facilitate alignment within the mother mold
- 17. The Mother Mold • Separator added to allow split in mother mold • Covered in wax paper to prevent sticking
- 18. The Mother Mold • Plaster cast bandages added
- 19. Mold ready for fiberglass
- 20. Fiberglassing-Materials • Gel coat • Fiberglass mat • Fiberglass cloth • Polyester resin • ½ in sandply plywood • Kitty hair body repair material
- 21. Fiberglassing-Steps • Spray 20 mil gel coat • Paint inside of gel coated mold with resin • Add resin-saturated mat • Work out air bubbles carefully • Reinforce areas of attachment and load using fiberglass cloth and resin • Remove from mold and trim to size
- 22. Gel Coat Fiberglass mat and resin
- 23. Install Rotating Bearing Support Fitting plywood ring to dome Plywood ring bonded to dome
- 24. Finished dome with silicone mold peeled off
- 25. The Eyestalk The pivot, the discs, and the eye
- 26. The Eyestalk-Materials • Wooden disc for pivot • 12 in diameter acrylic light globe • Various aluminum tubing • Steel pivot rod • Plastic pivot bearing • 3 in PVC pipe compression coupling • 3 in – 1 ½ in PVC reducer • Miscellaneous other PVC pipe fittings • ¼ in PVC sheet • Small multi-bulb LED flashlight • White translucent and blue gel lens covers • 80 mm Acrylic ball
- 27. The Pivot • Make a 3 in round disc 1 1/8 thick • Lay out lines along outside of disc as per photos of Dalek props and cut • Drill hole for eyestalk and pivot • Make and fit plastic pivot bearings to inside of dome
- 28. Dome with pivot Inside dome
- 29. The Discs • Cut discs from acrylic lamp globe using a hole saw • Enlarge center hole with step drill to fit stalk • Trim edges to size
- 30. Finished Discs
- 31. The Eye • Cut off the threaded portion of the pipe compression coupling • Cut the reducing fitting so as to make the tapered portion fit inside the compression fitting nut • Machine various PVC fittings to achieve eye geometry to accommodate flashlight used • Cut and insert translucent lens and gel • Extend wires for flashlight to go through stalk • Slot stalk to fit over pivot
- 32. Pieces as bought Some of the pieces prior to machining and assembly
- 34. The Eyestalk Cowl Fiberglass base, metal cowl, finish shape
- 35. The Cowl-Materials • Fiberglass cloth • Polyester resin • Bondo • Sheet Aluminum • 3/8 in Hobby plywood
- 36. Fiberglass Base • Place print coat of silicone on finished dome • Build directly on the silicone a fiberglass base for the cowl. • A cardboard mockup of the cowl was placed onto the base for testing purposes.
- 37. Metal Cowl • Using aluminum sheeting cut and form to shape based on cardboard mockup. • Bond aluminum cowl to fiberglass cowl base • Add wooden pieces to create necessary thickness
- 38. Finishing Shape • Bond aluminum piece to fiberglass base with fiberglass and bondo again. • With reference pictures handy, use Bondo to refine the shape and create details until the cowl looks like the on-screen Dalek cowls. • Cut out created by embedding a cut piece of polyethylene Bondo spreader.
- 39. Cowl with Bondo to form shape after sanding and on dome Finished Cowl after painting
- 40. The Dome Lights
- 41. Fabricate lights • Pre-made dome lights may be available for full sized Daleks from UK supplier. • Lights fabricated from camping lanterns, PVC, aluminum bar, and polycarbonate tube and rod
- 42. Finished lights
- 43. Finished Dome
- 44. The Skirt The framework, the panels, painting
- 45. The Skirt-Materials • ½ in sand-ply plywood for top and bottom of skirt • 2x4 studs to cut ribs from • ¼ in Luan plywood for panels • Wood Screws • ¼ in staples • Filler to eliminate wood grain • Primer and Paint
- 46. The Framework • Cut top and bottom of skirt per plans • Place and secure the top over the base • Add ribs at each corner
- 47. The Panels • Starting from the front glue and staple panels on. • Carefully fit, glue, and staple the remaining panels • Make desired cut out in bottom piece.
- 48. Painting Prep • Fill all staple holes and seams • Fill wood grain with filler of choice • Lay out and drill ball holes
- 49. Painting • Prime and sand • Paint sanding between coats till desired smoothness is obtained
- 50. The Bumper Top and spacers, vertical and angled sides, painting and decorative plugs
- 51. The Bumper-Materials • ½ in sand-ply plywood • ¾ and ½ in poplar lumber • Decorative round top plugs • Wood screws and staples
- 52. Top and Spacers • Cut top of inner part of bumper section as per plans • Make L-shaped spacer from ¾ in poplar to support vertical and sloped sides.
- 53. Vertical Sides • Add and brace vertical ½ in plywood sides
- 54. Angled Sides • Cut angled sides from ½ in poplar • Fit to bumper top and sides • Cut out center hole to match hole in skirt
- 55. Painting and Plugs • Fill screw and staple holes • Sand, Prime, and Paint • Drill holes and install plugs
- 56. Finished Bumper
- 57. Contact us/Build info • A full library of photos is available on flickr.com and will be updated as work continues on the Dalek • Access it here: https://www.flickr.com/photos/121782566@N08/sets/ • Like us on Facebook! “Dark Smalek” https://www.facebook.com/darksmalek • This presentation will be available for free on the web at http://www.slideshare.net/CarleighS/dark-smalek-build • Email the Dark but Small one with questions and he will try to find the answers... darksmalek@yahoo.com • For updates on progress visit our website! http://darksmalek.blogspot.com/
- 58. References • Plans used came from www.projectdalek.com • The dome mold http://www.brickintheyard.com/index.html • Eyestalk Lenses http://www.plastruct.com/Pages/OnlineProductDetail.lasso (To see detailed list of plastruct products for the eyestalk, go to: http://www.projectdalek.com/index.php?showtopic=1693 #entry23345) • Ribbed Mats http://www.mcmaster.com/#floor- mats/=s7hcjo • Dome lights (lens only) http://www.newark.com/moflash- signalling/50022fa/dome-clear-for-x125-sf125/dp/71C5929 • Dome light cage engineering specs http://www.projectdalek.com/index.php?showtopic=1811