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worzels NSD dalek

Started by worzel, Oct 15, 2009, 04:06 pm

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worzel

Oct 15, 2009, 04:06 pm Last Edit: Nov 29, 2010, 02:26 pm by Scarfwearer
youre starting part way through my 3 year build, so i'll give you a quick up date.

wooden plugs were made of the fender, skirt and shoulders, ready for making fibreglass moulds.

they were painted with 2k, so as to stop the gelcoat reacting with the primer, and then laid up during this summer.

Next, the final parts were made in the moulds, starting with...

the fender:

035.jpg

the skirt (split into 2 halves):

033.jpg

025.jpg

and the shoulders:

045.jpg

56 hemis were made from fibreglass, with discs (glued in place with rsin. The discs have T nuts pressed in from the reverse for fixing them onto the skirt.

008.jpg

017.jpg

here it is all stacked up:

008-1.jpg

I've made the eyestalk, gun, plunger and part of the ear cages, but here's the latest stage.

the dome:

001.jpg

0006.jpg



karsthotep

Oct 15, 2009, 05:47 pm #1 Last Edit: Feb 21, 2010, 05:22 pm by scarfwearer
holy crap that is beautiful work. 

I want notes, lists and answers by the time I finish this here Juicy-a-Box! WARNING: I am Thirst-ay! And it is Fruit Punch! And it is Delicious!"

metrosonus

Oct 15, 2009, 06:20 pm #2 Last Edit: Feb 21, 2010, 05:22 pm by scarfwearer
agreed !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

purpleblancmange

Oct 15, 2009, 07:52 pm #3 Last Edit: Feb 21, 2010, 05:22 pm by scarfwearer
Wow, that is a very tidy looking replica that you have there, very professional too and such a good job with the moulds and wotnot - you must have posted about this while I was replying to two other topics.  Very nice to see it after all this time!

I know you asked me to send you something, I will tend to that when I get back - been travelling a lot lately, but tomorrow I'm away again, so I will sort it when I get back.

worzel

Oct 15, 2009, 09:26 pm #4 Last Edit: Feb 21, 2010, 05:22 pm by scarfwearer
thanks guys for the kind words.

no worries PB, I understand youre busy.

i've been managing to find other things i can get on with, like the hemis.

thank God there are no other parts to make 56 of - lol

atomicgraph

Oct 16, 2009, 02:50 am #5 Last Edit: Feb 21, 2010, 05:23 pm by scarfwearer
wow!!! the skill of the people on these boards is amazing. great looking dalek are you gonna motorize it?

geminitimelord

Oct 16, 2009, 02:17 pm #6 Last Edit: Feb 21, 2010, 05:23 pm by scarfwearer
Quote from: karsthotep on Oct 15, 2009, 05:47 pmholy crap that is beautiful work. 



I couldnt have said that better myself LOL.  It amazes me the talent you see on here. That Fiberglass construction looks incredible.

DoctorWho8

Oct 16, 2009, 03:58 pm #7 Last Edit: Feb 21, 2010, 05:23 pm by scarfwearer
Everything looks like it was cleanly vacuum formed.  Beautiful.  Now apply this to a GRP TARDIS. ;)
Bill Rudloff

worzel

Oct 17, 2009, 08:03 am #8 Last Edit: Feb 21, 2010, 05:23 pm by scarfwearer
thanks for all the replies.

I have an electric wheelchair ready to fit inside, bought for only £6 off ebay & it was only 5 miles from where I live (it pays to be patient). At first, my kids loved driving it around the house, until i had a go and broke a kitchen cupboard door-lol

My wife would go berserk if i even suggested starting another project so soon. Hasnt anyone made a fibreglass tardis yet? Taking moulds from an existing wooden one would be relatively easy, plus you could make it in blue gelcoat and stick it outside without any fears from the elements.

If anyone wants to do this, i'll help with all of the advice i can.


DoctorWho8

Oct 17, 2009, 04:18 pm #9 Last Edit: Feb 21, 2010, 05:24 pm by scarfwearer
I think about 20 pairs of hands just shot up on your side of the pond in favor of this.
Bill Rudloff

Quote from: worzel on Oct 17, 2009, 08:03 amMy wife would go berserk if i even suggested starting another project so soon. Hasnt anyone made a fibreglass tardis yet? Taking moulds from an existing wooden one would be relatively easy, plus you could make it in blue gelcoat and stick it outside without any fears from the elements.

If anyone wants to do this, i'll help with all of the advice i can.


Scarfwearer

Oct 17, 2009, 05:49 pm #10 Last Edit: Feb 21, 2010, 05:24 pm by scarfwearer
Quote from: doctorwho8 on Oct 17, 2009, 04:18 pmI think about 20 pairs of hands just shot up on your side of the pond in favor of this.

That would unfortunately not be permitted by the bbc. Even discussing it here could get us into trouble. Talk to one of us by PM if you have any questions.

Crispin

DoctorWho8

Oct 18, 2009, 01:34 am #11 Last Edit: Feb 21, 2010, 05:25 pm by scarfwearer
Quote from: scarfwearer on Oct 17, 2009, 05:49 pm
That would unfortunately not be permitted by the bbc. Even discussing it here could get us into trouble. Talk to one of us by PM if you have any questions.

Crispin


I think I may have been taken the wrong way.  What I meant was that there are some people here who would like to go this route for their builds, but don't know how.  That's what was going on in my head when I said this, not misleading to think people should get their boxes manufactured just by one person unlicensed.
Bill Rudloff

worzel

Oct 18, 2009, 12:01 pm #12 Last Edit: Feb 21, 2010, 05:26 pm by scarfwearer
well, i've just laid out the grooves in 4mm wide car trim & the 1mm plasticard eye stalk and ear details.

014.jpg

worzel

Oct 19, 2009, 05:09 pm #13 Last Edit: Feb 21, 2010, 05:26 pm by scarfwearer
blimey, i've just noticed a line missing from the dome centre to the top of the eyestalk hole!!!!

thank God i havent gelcoated it yet.

worzel

Oct 28, 2009, 09:01 am #14 Last Edit: Feb 21, 2010, 05:27 pm by scarfwearer
here's the first pull.

Although its still untrimmed around the base, and came out of the mould good enough to use, I've decided to improve the finish by wet'n'drying, followed by T-cut (see small area at top left where I've test polished).
Also, the gelcoat crept over the sides of the 'D' profile groove lines, so I need to run a 4mm drill wrapped in wet'n'dry to neaten the edges.
After that, I'll make a mould of this to cast my final part.

Before that though, I've been side tracked by the cowl. The dimensions don't add up, so its time to do some research from reference pictures to try and get it right.

025-1.jpg