Dalek Trooper Weapon Build

[elkad]

Reference:https://tardisbuilders.com/index.php?topic=7302.0

I haven't gotten much time to do any projects these days.

I'm in the possess of making a Dalek Trooper Weapon.
Starting off with a 4" PVC for the handle, using a poster board ribbon as a stencil & mark off my cuts.



Using a duct tape 3/8" white PVC & a 1/2" conduit for the barrels.



I'm using 1/2" screw on pipe connectors that seam to slip on very easy to the 3/8 pipe as the bottom part of the gun barrels that attach to the handle.



I know the bottom parts of the gun barrels were glued together to the handle, but, I don't know specifically how they attached it, so I'm going with sanded tips &, sort of, bolted, by the pipe connectors.



I used a 4" coupler for the cap, manly a 4" cap was out of my budget price range. (Those cap things are expensive.) Stenciled it with another cardboard ribbon & cut it.



Cutting cap plates for the coupler peace, gluing & holding in a vice till it dry's.



I'm using a cardboard box to measure out how far apart my holes should be to mount the barrel conduits.

[elkad]

Using a 4 1/2" stencil to mark out the drilled barrel & screw holes of the cap.



4" Poplar dowel for the trigger handle inside the handle tube part.



#10 x 1/2" Zinc screws to mount the trigger handle



Drill a 1/2" hole for push button.



I'm using 1/4" threaded rod & nuts to strengthen the stability of the barrel. Honestly I don't know if the emitter is going to be heavy or light, so I'm hedging my bet & strengthening it now.

[elkad]

I experimenting on what to use that's light, strong, or what looks best. Cardboard paper mache, wood filler, (I haven't got the PVC rings yet), & trying to figure out how to make the lit emitter tip. I also need to get another type of wood, I tried drilling a ring but it kept jamming almost ripping my hand away from the drill.
The scraping tool is a modified tool to be used as a lathe rounding tool. (That's alot of tool for 1 tool.)

[elkad]

I've bin very desperate lately & haven't bin able to update this project form. Sorry for the wait.

Using a long bolt to hold the rippled conduit & make an electrical connection for the lamp.



I'm trying to use a pop bottle for the tip emitter. A bit of PVC for a spacer & unscrew-able tip to replace the LED if need be. (The actual light was too expensive for me.) I blocked off the bottom with flatten PVC & used an adapted caulking gun with two sized tubing to reach the bottom of the tip.



This is the center tube the rings go on. I put an inner ring inside to bolt to the conduit rods.



I smooth down the cardboard rings with plaster filler & paint.



I could have made an acrylic emitter tip, but I desperately wanted to finish making a vacuum former, even if it is a small. I made a small emitter tip out of the same wood dowel as the handle. I meticulously measured & drilled a hole in the middle, attached a small bolt rod, the same as the rod in the conduit, & attached it to my drill & lathed it. I would have done it different with acrylic rod, attaching it to my lathe drill.



I don't have the electricity or room to use a heating coil or toaster oven to melt the plastic in this holder, so I used my heat gun & continually heated it. I tried heating it from the top & I screwed it up on two points. 1, I heated it from the top, 2, I tried to put the tray on wile my vacuum was running. It sucked all the hot air out & solidified before I could get the holder in place.



The second time, I tried with Pop Bottle Plastic & it did this once I applied the heat. I acted like a shrinky dink, pulling the plastic out of the frame. So I went back to the opaque milk jug plastic.



SO, I tried a different approach. Making a quick stand out of two wire hangers & heated the plastic from the top & continuance heat all around. I found if I stop moving around, some arias of the plastic quickly cool off. I put the tray in, kept heating the plastic & turn on the vacuum. SUCCESS!



I found the ring tube was too long after measuring out were the rings were spaced, so I put it on my drill lathe & cut it with a hand saw. (smooth cut) , (This means more editing to my blueprint, expect an update image soon.)

[elkad]

I remade the battery pack & dremeled out a cavity in the handle. Spring elements & a 1" PVC sleeve that holds down the battery's & wire. You do have to unscrew the handle to replace the battery's, but it's worth it.



I was racking my brain on how to attach the emitter tip so I can still access the LED, wire, & bolts if I need to adapt or fix something. I was going for PVC tabs that screw & lock into place, but, IDEA, I've got magnets.



I just need to paint it now.

[elkad]

Stared off with a gray primer then a silver. I keep forgetting to put some disposable gloves on when painting, I got a Cyber Thumb.



I drilled a bigger hold in the cap to insert an LED light, with silver reflector. I painted the emitter light inside & out with a red gloss tint. Then painted a strip of black at the top & silver one on the bottom.



I shouldn't have painted the inside, as soon as I put the sleeve over the cap, it became stuck, & I dropped the LED inside. SO, I had to drill out a larger hole & make another holder for another set of brighter LED's. I did a test with the LED holder, & the light wasn't just bright enough for me.



I know the head & tip is silver, but the barrels & gun grip should be a darker silver. More sanding to darken it, or add more layers of paint.



I'll have a video & selfies at some point, keep an eye out for that post.

[Volpone]

If I may, a black wash on the barrels could be very rewarding.  It will darken it but it will also give it more depth and contrast as the black settles into the nooks and crannies while mostly leaving the high spots silver.  I might try India ink if I were doing it. 

[elkad]