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worzels NSD dalek

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

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Oct 28, 2009, 10:27 pm #15 Last Edit: Feb 21, 2010, 05:28 pm by scarfwearer
thats a fine looking pull you got there, and again the craftsman ship is top notch. what does the gel coat do? i don't have much experience with fiberglas  so far i've only used it to reinforce my joins on the skirt and base.


Oct 28, 2009, 11:15 pm #16 Last Edit: Feb 21, 2010, 05:28 pm by scarfwearer
hi, gelcoat is a thick coloured resin, painted on prior to the fibreglass matting. It sets hard and sticks to the matt to form the shiny finish.


Oct 29, 2009, 09:29 pm #17 Last Edit: Feb 21, 2010, 05:28 pm by scarfwearer
i see. it's like the "foundation". do you let it dry completely before you apply the matting layers?


Oct 30, 2009, 06:07 pm #18 Last Edit: Feb 21, 2010, 05:28 pm by scarfwearer
paint on, let it go tacky to the touch (approx 3 to 4 hours), then apply resin/matt.

I paint 2 thin coats of gel, each 3 hours apart before resin/matt.

I do this to make sure its not so thin in places that you can see either matt or sunlight through it.


Oct 30, 2009, 10:10 pm #19 Last Edit: Feb 21, 2010, 05:29 pm by scarfwearer
thanks for the tips worzel, it'll be a while yet before i'm to the point of making a dome but i need to get it all clear in my head before i start.


Nov 10, 2009, 07:31 am #20 Last Edit: Feb 21, 2010, 05:30 pm by scarfwearer
the dome has been polished and filled where there were imperfections and then placed on a board ready to make a final mould from it.


theres a risk that it might get stuck, as it has no sticking out edges to pull on, so I'm hoping the 3 tiny drill holes I've made in the ears/eyestalk will let me blow it free with my compressor.

fingers crossed


Nov 15, 2009, 12:05 pm #21 Last Edit: Feb 21, 2010, 05:30 pm by scarfwearer
heres the final mould...


next job is to use it to make the final dome, then onto the dreaded cowl


Nov 15, 2009, 05:12 pm #22 Last Edit: Feb 21, 2010, 05:30 pm by scarfwearer
Looks like a Dalek mixing/salad bowl.  Tasty.
Bill Rudloff


Oct 18, 2009, 09:01 am #23 Last Edit: Feb 21, 2010, 05:34 pm by scarfwearer
Understood. I just had this vision of loads of people signing up here for a GRP replica, closely followed by the guys in suits and stern faces...  :o



Nov 29, 2009, 12:00 pm #24 Last Edit: Feb 21, 2010, 05:35 pm by scarfwearer
funnily enough, thats what some people advertise them as on ebay-lol

well the new dome is made and the boring but time consuming progress of getting it ready to mount has taken place since my last update.

the head dome needs a flat base inside to rest on the neck wheels, so that it can rotate when the dalek looks left/right.
This flat base also supports a bracket to hold the eyestalk pivot, allowing the dalek to look up/down.

here's a pic of the flat perspex base (yes i know it looks like the face of the marshmellow man on Ghostbusters-lol)

Also, you can see the blocks of wood glued to the inside of the head dome that the base screws onto, and a cardboard mock up of the final piece of fibreglassing to make (the cowl that bolts to the front of the dalek head dome, like a visor).



wow. those moulds are pricelless. excellent job