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Collapsible CNC-Compatable Capaldi Tardis with Constrained Component Count

Firstly I'd like to give a huge shout out to Vyacheslav Talanov, and their plans entitled "Season_5_TARDIS_Plans_v4". These plans were the spark I needed to make my own Tardis after many years of dreaming.

My design stage began on the 7th February 2026, by making a 3D shell using the above plans, after many iterations I eventually locked in a final design on 20th of April. I took ideas from other builds and these helped me made some key design decisions.

Firstly, my Tardis will be collapsible, becoming 16 pieces in total; the base, 4 pillars, 3 wall panels, 2 doors, 4 lintels, the top pyramid section and finally the lantern. I hope this will make transport more practical.

Secondly, I have designed my Tardis to have as few parts as possible while still meeting all my requirements for looks and functionality. The part count stands at 286 in total (-screws).
177 (62%) parts will be cut out of plywood using a CNC machine, reducing the workload.
84 (29%) parts will be engineered by myself, and
30 (9%) will be bought off the shelf
By making efficiencies and removing any redundant parts I was able to reduce the count by approximately 19% in total.

Thirdly, its mobile! 4 heavy duty castors on each corner of the base will provide 6cm of clearance. The castors are retractable with foot operated pedals inside, which I'll cover in a later post. Sadly i made the difficult descision to remove the castors (for now) see Update 4 for more details.

Thirdly, I have allowed for bulb and lantern access from within the Tardis, the bulb will be mounted on a platform that pivots 90 degrees allowing easy access for changing the bulb. I need to consider how to attach the lantern easily and safely, I want to avoid resting a ladder on the old girl, and I'd rather minimise leaning over the Tardis. In a dream world, one of the roof panels would swing up allowing internal access closer to the platform it rests on.

The CNC items all fit snuggly inside 7 sheets of marine plywood, 3 sheets of 18mm and 4 sheets of 12mm.

Like all Tardis Builders, I am working to a strict budget, my initial aim was to keep costs below £1,000, and I’m glad to say I’m on track. So far the cost of the build stands just above £780, which includes all the materials I require, thanks to my efficiencies and discounts I was able to secure. This leaves roughly £200 for CNC machining costs (fingers crossed).

The final design does slighlty deviate from the Talanov plans, most noticeably the lantern, which is slightly too large, but I can’t argue with £30. The diameter of my lanterns base is 220mm and the lense itself is 7"h x 9"dia.

As for paint, after much deliberation and many scrutinised screenshots, I am going with a 2.5L tin of Valspar Garden Exterior Wood Paint in RAL 280 30 30.
 

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first attachement credits (
) deleted user.

Update 1: after salvaging a genuine nautical lantern from a boatyard I dissasembled it and began removing the Chimeny to allow for a more accurate top. The bottom of the latern has entirely rusted out, so I used evaporust to remove the metal that was beyond recovery. It was a lovely treat to see the brass fixtures for the first time in likely decades. Also look at that before and after with the glass!
 

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Update 2: Lantern has been paint stripped (as much as I can) and the worst of the rust has been removed. I degreased and primed in grey spray paint last night. I also have attached a sample of the RAL 280 30 30 paint in various lighting while I evaluate the shade :)
 

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Update 3: The lantern has now been decently restored and is in a stable condition while it waits for the blue paint. I have begun modifying lampshade (which I purchased from here) to become the new cap. I am reusing the top of the orginal chimeny and cutting the top and bottom sections off the shade to achieve the right profile. I will attach photos when I get time. I am not a metal worker so the parts will be joined using bodywork filler used for automotive repairs. I have looked in countless antiques shops, for what I struggle to think of a more apt word than "nipple" at the top with no luck. I plan on threading some nuts onto a bolt and grinding it down to sculpt this part, see Update 5 to see how this went.
 

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I refuse to call it anything else than the "nipple" as I'm sure others do too! It's great you were able to secure a real fresnel, I'm sure your modifications and restorations will make a great lamp with a nice story behind it. Your choice of paint looks spot on as well!
It's incredible that you can construct the whole box from 7 sheets-worth of plywood, I'm very interested to see how everything comes together, this might become a new common method of TARDIS fabrication!
Best of luck!
-Beren
 
Update 4: The new lantern top has been dry fitted and is looking pretty decent! I will share the plans of the tardis now i have finally stopped tinkering with it. I am having great diffuculty finding a local CNC machinist, this is one downside to the flat-pack construction method.

Regarding the wheels, in a bid to reduce costs and complexity these plans had to be abandoned, I will attach a sketch of how these pedals would have worked in case anyone wants to use the concept for thier own project. I had planned to use these castors.foot activated wheel levers.jpg
 

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I have now uploaded my final plans to the Sketchup 3D warehouse, free for all to use and adapt as you like,
all I just ask that you don't sell the plans and keep them accessible. If you do use the plans, consider crediting me. Thanks, :)
 

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Tangent 1: When I first collected my nautical lantern I was praying for some kind of makers mark or even a ship name which would reveal the things history, but even after dissasembly I couln't see any such hints. Until, while sitting with the completed lantern on my sofa, measuring and modeling its digital counterpart, I noticed some faint white text on the glass (C.B.Ltd 9X7) bingo!

Firstly and simply, 9x7 does indeed relate to the overall dimensions of the lantern 7 inches tall by 9 inches diameter.

Now for the rich lore, C.B.Ltd (originally Chance Brothers & Co), was established in Birmingham England in 1824. A few snippets from this companies history: in 1850 they established thier "Lighthouse Division" and began manufacturing fresnel lenses. in 1915 they began production of Heat-resistant glass products, and began manufacturing smaller items such as Orlak tableware, laboratory equipment and lighting globes. in 1920 they began manufacturing lighting for airport runways. I would hazard a guess that my lantern dates somewhere around 1915-1920, because my lantern has a similar form to those used on runways and would likely need to be heat resistant because of bulbs close proximity to the lense.
 
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Update 5: My first attempt at crafting the "nipple" started by selecting two large bolts and threading them onto a bolt, I chucked this into my pillar drill and began carving the shape with my small angle grinder as it spun, this looked promising at first. But issues arose because the bolts were not the perfect match for the bolt securing them, and they worked themselves free and lost alignment. I went back to the drawing board and visited yet another antiques shop, here I found the unexpected solution to my problem, a thimble. Attached is a 3d model of how it would compare to the real prop.
 

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