New Year Eve Of The Daleks Mini-Gun Build

[elkad]

The only thing I thought of was before starting this is, will I finish before the episode is broadcast?

Reference: https://tardisbuilders.com/index.php?topic=11097.0

OK, to start off with I'm making the laser emitter rings, the black panels that encircle & hold the lasers in place. This is my first measurement, & its lousy. My compass kept slipping on me, the pencil lead, the sharp poky stand, & the settings dial.

[elkad]

To save time, I'm going to use a drill & rod to spin the barrel. If I put a motor in the front were the black cylinder is under the lasers, I'll have to work out a connection system or drive train. With the bar attached to a drill, all I have to do is bolt it in place.
I'm also going to have to figure out how to install bearings in the top & bottom of the spinning lasers & bottom gun boss attached to the gun ribs.

[elkad]

1 1/2" to 1" reducer cut down for the tip of one of two gun boss's



I dremeled down a 3/4 to 3/4" coupler to slide easy up & down the pipe, or around in this case, because the 3/4" coupler go's into the cut down 1 1/2" reducer gun boss. This will help make the gun boss spin along with the gun ribs like a caster.

[elkad]

Re-did the angles & using the first gun boss as an example, this is how the gun will look. I also cut 3" length 3/4" pipes. I also found that depending on the size of the laser emitters determines the angle of the gun ribs to the gun boss. So getting the right size pipe is difficult, & am going to stick with the 3/4" pipe.

[elkad]

Ok, I'm making the bottom gun boss, cutting the disks & the 2" pipe base.



Lathed down the gun boss base, starting with marking the line where the lip & lathed part is.



Glue the disks to the gun boss base, sprinkle with baking powder, I found it makes super glue dry quick, & lathed the disks down level to the other side of the lip.



I clamped the gun boss to drill the main barrel hole. 1" is to small & 1 1/8" is to much, the best thing to do is drill a 1" hole & sand out the hole till it fits snugly. Did a test hole.

[elkad]

I found its best to make the disks with a 1" hole with the hole saw first instead of just making the 2" disc alone. Drilling the hole can brake the glued disks. Its best to mark the holes with the hole saw, cut the 1" hole then go back to the 2". It's very difficult to hold a 2" disk & drill the 1" hole.



I marked out were the top & bottom part of the gun boss is to know where to stop sanding down the angle for the bottom part.



The two parts will NOT be glued, since the top part will be spinning freely with the gun.



Marking off where the rib holes go, spinning the boss tips on the lathe.

[elkad]

Drilling the holes on a 45 degree angled drill press, starting with a small hole to mark the bigger one.



Got some needles from the dolor store. Best thing I could get on short notice, & was a $1. I was thinking of getting or finding plastic rod for a lighter gun, since it will be spinning, & don't need heavy metal rods suddenly detaching & spinning out of control.
Use a 3/16" hole for a snug fit for a 5.0mm rod.



Cut out the laser barrel ring stencil, & the 6 5" disks to cut out with the largest hole saw I have.



Getting closer to the more difficult parts, like how to attach the spinning gun barrel to the main shaft.

[elkad]

Using my hole saw size board I line up the sphere half & the drill bit. Once it's lined up I replace the regular bit with a stepper bit & slowly drill the hole to a 1" hole & use WD40 so it doesn't crack.



I Dremel the hole smooth & sand it till its a tight fit for the pipe.



Then I line up the pipe to the other half, give it a spin to see if the pipe & half's are level using the half line as a level. Mark off the pipe & cut the other half.



For the disk I cut a 7/8" hole for each laser emitter & sanded them to fit smoothly. The center is a 1" hole.




Put the pieces together to see a good start.

[elkad]

I put all the discs together for sanding, then took fore out to cut & sand smaller discs. Now glue together & sand any stray glue goobers, & check the alignment for additional sanding.



I made the tip insert for the center gun mount out of a 1 1/4" hole saw & 7/64" drill bit.



Made a quick video.

[russellsuthern]

That's looking really good!

Great work.

Russell

[elkad]

The best way to sand a metal rod, attach it to a drill & spin it. CAUTION, wear gloves when sanding, the paper & rod gets hot quick.



I couldn't find any pipe plugs for a 3/4 pipe, so I sand down some 1/2" threaded connectors.



I marked off the center & drilled a hole for the metal ribs.



This part is the brace behind the rotating gun barrels. Made form a 1" pipe cap & 3/4" coupler. Keeps it from sliding back. I couldn't find a screen shot of the brace, so I used my artistic license to make one.



A quick look of the brace on the gun.

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[elkad]

[elkad]

Using a 1/4" bolt & nuts & 2 3/4" disks I can attach the bolt rod to the springing barrel of the gun. I also made a 3/4" disk for the tip cover for the center LED. The 3/4" pipe is a spacer for the cover.



For the laser emitter tips I used a 1/2" tube, I forgot the specific thickness or schedule pipe. I cut it, lathed it, & sand it down.



Tip measurements.

[elkad]

I found the first 3/4 coupler was too short to fit wiring for the LEDs so I attached another for space, I can drill a hole in the middle to wire the other LEDs in the laser emitters.



I plan on making a gun box & handle to hold it like an actual mini-gun. Thanks to the Dalek builder plans I made up a quick stencil to mark out on the PVC sheets.




Time to paint some parts. Let me know, I'm having trouble with the color, are these pieces suppose to be black, or a dark gray?

[elkad]

Painted the parts, now for the electronics. I'm using what's known as a slip ring. It uses a stationary spring on a rotating metal ring or drum. I used a ground down washer for the ring, straw on the bolt & a couple plastic PVC rings to block the connection from the ring to the bolt.



I drilled holes in the spinning ring to run a wire connection to each of the laser emitters.



Wiring all those wires was he.. a.. not pleasant.



Ground wire for the bolt & the positive wire wound up the bolt to the slip ring at the top.