New series dalek revamp

[brenk9carter]

I recently acquired a new series dalek from a friend who has moulds taken from the originals, this is one that hes had for a little while and hasn't been finished. I bought it off him and im upgrading him, going to be repainted in the standard bronze colours and ill put a load of electronics inside including lights, a voice changer and an electric wheelchair so i dont have to shuffle it with my feet
Anyway on with the pics  


Ive disassembled him as much as possible so that i can sand him down and repaint so far

[russellsuthern]

He is going to look lovey bronze.

Looking forward to seeing your progress.



Russell

[No More]

Interesting to see that colour scheme on a New Series Dalek - it works quite well actually in red&silver.  Nearest we've seen is red&gold for Dalek Supreme in The Stolen Earth/Journey's End.  Any idea what made the original owner go for red&silver?

[Angelus Lupus]

I have to agree here: that colour scheme is very nice. Might have been cool to see something like that in the show.

[brenk9carter]

Interesting to see that colour scheme on a New Series Dalek - it works quite well actually in red&silver.  Nearest we've seen is red&gold for Dalek Supreme in The Stolen Earth/Journey's End.  Any idea what made the original owner go for red&silver?

I think he just wanted something different from ordinary dalek colours so went with that, i do like it but i personally prefer the standard bronze colour scheme

[brenk9carter]

Havent quite got my head around the project dalek forum yet so until then ill just be posting updates here but, i got a wheelchair now  
Obviously this is to power him, i want to make it remote controlled also so i have the option of sitting inside and driving or controlling him from outside the shell.  


Stripped down and ready to modify


As you can see i haven't done a whole lot yet but now i got the chair i can start the proper work  

[elkad]

RED DALEK MY FAVORITE COLOR! 

[brenk9carter]

Soo, been a month since an update so here we go.

Done a surprising amount of work to the wheelchair to make it fit and work properly, the first thing was to take off the front stabilizing wheels, however these were part of the suspension system which meant that when they came off, the motor wheels had no support, so i made a couple of supports out of some spare aluminium on the little lathe.



So then went for a test fit to realise that the cross bar that the castors are on is too wide  

So that got taken off. My dad took it to his factory and got one of the guys there to cut it down and weld it back together again so now it looks like this.

Now it fits properly however the castors are on the back of the wheelchair and i wanted them on the front. I could've made it really difficult for myself by taking off the motors and putting them on backwards or putting the castors on the front but instead i simply swapped over the positive and negative power cables to the motors so that backwards is now forwards, meaning the castors are now on the front  

( yes I've still got more)

I plan on having the top half of the dalek hinged so that it doesnt take 2 people to enter, it'll just be a case of fold it back, climb in and then fold it forward over yourself, this meant cutting the top half off    

I did this with an oscillating power tool that i borrowed from work, did the job wonderfully  


And finally in todays update...
Made a mess with the angle grinder today, cleaning out the inside so that its ready to have more fibreglass work done to it, this includes adding reinforcing strips around the top and glassing in the seat and location for the wheelchair.

Pheww glad i didn't leave that any longer  

[brenk9carter]

And after that lengthy update here's a slightly shorter one, after i finished grinding the inside clean i started to make the support for around the top of the skirt, originally it was just going to be some 20mm x 20mm off cut from the tardis around the rim, i got this made and fitted in roughly, this helped straighten things out, however was still very flexy, so instead opted to use a single piece of plywood ( again left over from the tardis)

This is the original plan before screwing them all in place

And the plywood once fitted, i simply flipped the skirt upside down and marked around it then jigsawed it out.
It will have a big ol hole in the middle so i can fit inside, it will be fibreglassed in when its ready.

[brenk9carter]

Just realised i didn't post this but, i made one of the gun parts at college using the lathe and milling machine, i turned all the diameters and used the dividing head on the mill to cut the holes around the outside.
So just a short one to show that off, im finishing college soon so im going to have to make the other end part either at work or my dads factory  

[Rassilons Rod]

I saw the first one of these guns that was made, when I worked at the BBC in Park Royal (where they shot the Gatwick Scenes for Evil of the Daleks).

A fellow fan made it in the machine workshop, primarily because the fx department knew he was a fan.

He was working in absolute secrecy because the Daleks' return hadn't been announced yet. He avoided me like the plague because he knew I'd recognise it and spent all day avoiding me

He also carried it upright constantly, in the hopes of convincing people it was an antenna : D

I do love well worked metal and yours looks awesome

[brenk9carter]

So a lot more has happened since i last updated

It started out by cutting a big hole in the middle of the plywood on the top of the skirt with the jigsaw so that i can fit in


And then fibreglassed it in place.

Now its really rigid which is a lot better than before

And then... wheelchair fitting time  
As you can see the chair has a bit of plywood which spans the width of the inside of the dalek, it has 4 locators for the chair so it just slots in place easily.

And then.. more fibreglass, i hate using this stuff however it makes the join super strong.


And of course i had to take it for a test run  

And just stacked it up to get a feel for what its like inside  ...
A but cramped but otherwise totally fine.

Also just today, i started to make the other end part on the gun on the little lathe in the garage, I'll need to take it to my dads factory and use a mill to put the holes in the side of it yet.



Anyway, thats enough for one update i think, next stage is to clean up all the fibreglass i think, and hinge the mid section.

[galacticprobe]

And just stacked it up to get a feel for what its like inside  ...
A but cramped but otherwise totally fine.

The ultimate killing machine is coming along great, Bren! Just one question... how many car crashes did you cause during your little jaunt in the demon pepper pot because drivers were so busy looking at you, or looking around for any filming crews rather than watching the road?

Brilliant!

Dino.

[brenk9carter]

Well well, its been a while hasn't it.

Quite a bit has happened since last update soI'll try and make it brief.

The wheelchair is glassed in properly and I've built a seat up on it so im not crouching inside.
I made a foot rest so that my feet wouldn't get caught on the ground and get hurt, this also acts as a stability aid as i made a section that rests on the front of the wheel chair to stop the dalek tilting forward.

The seat, itll have cushioning on it eventually


I also made a holder for the joystick.



I sanded back the outside a bit to key it for painting, needs a bit more rubbing down yet but i reckon thats the main skirt construction complete.
Also not hinging the shoulder section anymore as i dont want to overcomplicate things, it'll just be held by locators and gravity mainly.


So hopefully soon i can get some primer on it    then i need to nail down the right colours  

[brenk9carter]

A few good things have happened recently, first thing is that I've made and installed the locator pins for the shoulder section, so when assembled it should be in the same place each time without wobble

These included glassing in some wood blocks on the shoulder section to take the holes.


Also rubbed down the shoulder section completely so the skirt and shoulders are ready for primer