South East Tennessee TARDIS Build

[izlear]

I've been putting this off for far too long, but here is my story so far.
I've wanted to build a police box for a long time, and after I finished Grad School I decided I wanted to do some of those things I had been wanting to do, so the TARDIS is my first of those things.

I started the project sometime in august (of 2010) and at this time I have gotten the walls the base and the walls all but finished.

we thought about construction for some time.  with the only requirement being that it had to be able to be taken appart.  so we got at it.

the base was the first thing that we worked on, Deciding on the size and the model we wanted to make was the hardest part.  once we figured it out though we started building.  the base is heavy!  probably over engineered!  The thing is massive.  Once we finished it we weighed it and it clocked in at 92 lbs, since then we have added to it, so it probably weighs more now!





Next we made the corner posts with the build up method, nothing too dificult.  To get the right sizes w got several 1X6s and 1X10s and ripped them down to the morea approriate sizes, that method seemed to work and we ended up with appropriate sizes  we found that counter sinking the screws was a good idea




After the corner post we began the walls:  Got mateials and cut the frame work.  Then bebegan placing it and made a single wall first.  Once we figured out the process it went pretty fast.  The hardest part was spacing the crosspieces appropriately, we did eventually get it down to a science with a wooden spacer and a square.




Once the walls were up we began spacing corner posts and mounting them with some metal mount plates that will be used to make the corner posts removeable




Once we got the corner posts up we worked on mounting the walls.  the walls are mounted with brackets similar to those that are on a tool box.  We had to angle the wood that the attaching piece were on so that it would pull the walls IN to the corner post and not just keep it in place.  THEY worked.  (we were impressed by this)  we went this rout in an effort to keep cost down. We also had to cut notches out of the bottom of the walls so that they would fit around our corner post brackets and reach the base.





Now we are about up to the present.  Next was windows.  What we did was make a router jig so we could rout the windows from the back of the walls, and I have to say they look nice.  It was actually one of the simplest processes in the whole build.
<img>http://www.flickr.com/photos/98521281@N00/5198623522/</img>;
<img>http://www.flickr.com/photos/98521281@N00/5198028069/</img>;
<img>http://www.flickr.com/photos/98521281@N00/5198623660/</img>;


Now we have all of our materials for the windows and the next step is to build them out.  the Windows are actuall made of a material called lexan.  My father in law recently built and experimental light airplane and this was the material he used for the windshield.  Its pretty durable.  He had some left over so we made our windows out of that.  We are trying to make the window frame pieces as simply as we can so we are cutting them all as long pieces instead of the shore pieces suggested in the build guide.  We are going to rout out the areas that need to cross the other pieces.  We'll see how it works out!  



A window mock up to see where we are going:



A few more images here:  http://www.flickr.com/photos/98521281@N00/

[Scarfwearer]

Welcome aboard!

Looks like you're making great progress...

Just to help out with the pictures: the IMG tags need square [] brackets, rather than angle ones <>. The http address in between needs to be the photo itself, rather than a web page with the photo in it. The photo URL will normally end in .jpg
Once the forum has it in this form it will upload the pictures from flickr for you.

Alternatively you can upload pictures directly from your desktop using the Add Pictures feature. Remember to resize them first though, as pictures straight from the camera will be too large.

Crispin

[izlear]

Thanks,
I think I got it now

[lespaceplie]

Which version of the box are you going with? At a glance, it's looking like a Season 18 (as it had been planned rather than how it shrunk). The latches on the inside corner posts is an idea I will file away for my own future box.

[izlear]

The version I am making is a slightly modified version of the plans that Doctor Iz made.  I think it is the TARDISy police box, I am going to take the extra tier out of the roof when I get to that point, It is going to be a kind of amalgum of versions, but yes I think it is similar to the Season 18 build.

[DoctorWho8]

Well done.
Bill "the Doctor" Rudloff

[dragnet767]

Do you have a rough cost for the wood? I'm going to start planning my build soon and I'm trying to get a guess on materials cost. Also what do you do about the glass(?) "police Box" sign at the top? Can these be bought or do they have to be made and if so...How?

Yours is looking really good.

[izlear]

Sorry for taking so long to reply to this!  I have kept all reciepts and am planning on making a cost guide when I am finished.  A rough estimate on the wood I have bought so far (which is the main build, I will begin stuff above the doors probably tonight!) I'm gonna guess I have about 200$ in the wood so far, maybe a little more.   But I have used some wood that was given to me (but only a little bit).

As for the signs and the windows I am using a material called lexan (kind of like plexiglass).  For the signs I am covering the lexan with Vinal decals which I am going to have printed at a shop.  Actually I should have my door sign tomorrow and I am printing them to be put on a piece of lexan to be added to my phone door.  This decal is only costing me 12$ and I expect a similar cost a piece for the decals for the top light boxes!

Thanks for the look at my build!  

Do you have a rough cost for the wood? I'm going to start planning my build soon and I'm trying to get a guess on materials cost. Also what do you do about the glass(?) "police Box" sign at the top? Can these be bought or do they have to be made and if so...How?

Yours is looking really good.

[izlear]

Ok so I am finally getting around to updating this:

We have now completed the window frames and have the Lexan cut out.  I have not attached the frames to the lexan yet because I want to paint first



We have also attached the doors on 3 hinges a piece.  And have also put the lock on.  The lock has actually worked out pretty good!












I also have put a latch on the bottom of the left door to act as a stop


Next is the phone box frame:



I got my sign today ( a vinal decal that I am putting over lexan) and am looking forward to getting that all finished.

[DoctorWho8]

Looking really nice.  What model of TARDIS are you going for?
Bill "the Doctor" Rudloff

[timerotor]

YUM!
That looks like a classic series build to me! SO very well built... looks like its gonna be one of the best out there!
Can't wait to see how this one turn out!
best of luck.
Timerotor

[Rassilons Rod]

Looking beautiful!

[izlear]

Wow thanks All.  It is a classic design the plans I am basing it on is the same as Doctor Iz's I believe it is the "TARDISy Police box".  But I am planning on taking the extra Tier out of the roof.  It is still going to have the slant to the roof and not a flat top though.  We have developed a lot of the build methods ourself, but we are using the TARDIS build guide as a . . . well guide. 

a lot of our stuff is over designed and very much too heavy but I am proud of what we have done and I am glad you guys approve.  Hopefully I will have new pics soon!

Looking really nice.  What model of TARDIS are you going for?
Bill "the Doctor" Rudloff

[izlear]

The sign Mounted on the Lexan:


A preview of mounted sign:


And I THINK this is the paint I am going to use.  Celestial Blue (lowes Olympic paint) painted onto black:


what do you guys think?

[Rassilons Rod]

Lovely colour I'm always a fan of rectangular panels too Nice sign! Forgive me if I missed it, but which version are you building?