Welcome to Project Dalek

You need to be a member in order to access our content.


Click Here To Join!


For instant access to the plans and all Forum features, choose Active Membership.


  • Content count

  • Joined

  • Last visited

  • Days Won


cjorgensenmd last won the day on March 16

cjorgensenmd had the most liked content!

Community Reputation

11 Neutral

About cjorgensenmd

  • Rank
    In the jungles of Skaro
  • Birthday

Profile Information

  • Gender

Recent Profile Visitors

52 profile views
  1. Well I've had a very busy week and weekend, getting prepared for and demonstrating the Dalek at two events to help promote my local hackerspace. I learned a lot form actually driving around my Dalek and I'm hoping somebody can point me in the direction of opportunities for improvement. I started off by attaching all of the oil seals I have to the skirt and then attaching the skirt to my base. I am still missing 3 oil seals, but I will cast those out of fiberglass resin later. Given the time constraints, I ended up rigging together this microphone from the electret mic provided with Andy Grove's voice changer kit, basically attached via long extension wires to the arduino board under the seat. I mounted it within a spare hemisphere (for noise reduction) and tried to suspend it with these plastic spring things, but they both failed shortly after taking this picture. Before my next outing, I want to be able to use a compatible headset mic with a push to talk feature. this mic was picking up too much ambient noise and was triggering my dome lights like crazy. The voice changer worked great though! I need to mess around with the code to see if I can add a soundboard type feature with momentary push-buttons to trigger different sound effects. I gave up on the aluminum ear cages, so I cobbled together these lasercut ones. Unfortunately our hackerspace laser is out of alignment by a degree or two, so the ears were not quite square. I ended up using an extra 1/8" piece of hardboard on the base of the ear in order to get the right height. I painted them with metallic silver paint and put them on the dome. Fellow members of our hackerspace suggested trying lost-PLA aluminum casting of the ears in the future, so I might be trying that later... I did not sleep Friday night because I was filling in imperfections on the shoulders with Bondo, sanding them down and giving the entire upper half of the Dalek a fresh coat of paint. It took almost 90 minutes to completely mask off the neck bin, but I think it was definitely worth it in the end. I might replace the neck blocks in the future with rubber cast blocks because the current ones don't hold up to much abuse, being ball bearings simply hot glued to wood... Finally, all that effort paid off. I was able to bring the Dalek to both events and it was a huge crowd draw at both, especially when I was inside, piloting around. I will definitely be wary of small children in the future though; they all wanted to punch the hemispheres and tried to climb the skirt. This thing really is a pain in the butt to move though. I estimate the current weight without an operator is close to 250lbs. I have been convinced that I need fiberglass fender, skirt, and shoulders. Members from the hackerspace were so impressed that they are willing to pay for the cost of materials for me to make a second one out of fiberglass so they can use it as advertisement. Woohoo! One final thing I noticed while driving this thing around: My current dome rotation and eyestalk mechanism is a disaster. The eyestalk is all one piece right now, so I cannot attach it before putting the fiberglass dome on and after the dome is on, I have no way to locate the holes for the pivot mechanism. Additionally my arm got very sore from moving the dome around all the time. I want to transition to a fully motorized dome and eyestalk, controlled from a handheld joystick. Can anyone point out any particularly good options for motorizing the dome?
  2. Today i tried to start on the ear cages, but the waterjet cut aluminum struts were not consistent or accurate, so I have given up in this idea and will instead attempt to lasercut MDF ear cages and then paint them a metallic color. After that fiasco, I decided to attach the bulb holders to my dome and tidy up the dome wiring. These terminal blocks make wiring a breeze. The capacitor on the leads going to the dome lights ensures a gradual fade off, similar to incandescent bulbs. And finally, all assembled. Not too bad.
  3. Thanks for the vote of confidence Mike. Our hackerspace let me know this weekend tat they want me to demo the dalek next weekend so I got a lot of work done this weekend. I've decided to name my dalek Edvin after my late grandfather who gained US citizenship through military service. I started off by taking my fender and coating it with leakseal, a type of liquid rubber in aerosol form. Eventually I want to get it coated with some type of hard truck liner compound, but this will do for now. I then sanded down the rough spots on my skirt and broke out my new gravity feed spray gun to paint the skirt. It took until the end of painting for me to realize that I should have filtered the paint before spraying . My in-line filter got clogged and it was takin g 10-20 minutes just to paint a single panel. Right at the end I tried thinned, filtered paint and I was able to do the last panel in 20 seconds. Oh well, I suppose this is a learning process. You can see some of the hemis which I did not prime above. When I primed my first batch of hemis, roughly 25% had a very bad reaction between the acrylic, primer, fiberglass resin, and the sun. Basically, i sprayed them and let them sit in the sun to dry and subsequently, a large amount had the tops dent in. I used some of the less noticeable ones on the skirt, but most were not salvagable. I went ahead and painted the dome and shoulder section as well as I was practicing with the paint sprayer and I have found that it can sometimes be easier to pick out small imperfections when everything is the same color. I still need to smooth out the shoulder's top collar, but the dome turned out surprisingly well. You can really see where I need to sand down the odd lumps and bumps in that last picture above. I hope to get the surface perfectly smooth before I make the Fiberglass mold. For next weekend though, I think using these current shoulders will do just fine. I also stated attaching my seals onto my skirt, but forgot to take pictures. Here is an updated picture of the neck rings as they currently stand: Finally, I spent most of my weekend working on the electronics. I was previously running some things off one battery and the remainder off the other batter, but that was leading to unequal power usage issues, so I decided to rig together a better way of managing all of the electronics. This is my rough wiring setup. I get 24V DC in either from an AC power supply or from the batteries and I can choose which one I use by turning the switch on the right. The 24V then goes to the Voltage regulator which should put out 12V DC. All power also runs through this digital multimeter readout I got on Amazon so I can measure the power draw of different accessories. Also inside the box are the MC400 amplifier for my speakers and an arduino with Andy Grove's ultimate voice changer shield. I have this unit driving a relay to flash the dome lights which are just LED tail lights inside ping-pong balls. Rough wiring. Much more cleaned up now. and bolted to the underside of my seat. Yay it works! It does use quite a bit of current though...
  4. I managed to get my first stack together before Alamo City Comic Con. My Dalek was nowhere near complete enough to bring though, but I did see an interesting Davros chair: I got back into my build in January 2017 with the fender construction. I had already purchased a used non-functional wheelchair on craigslist. I refurbished the batteries and got it running again. Then I hacked it apart and learned to weld at my hackerspace. The end result being probably the ugliest welds ever seen, but my wheelchair was now a tripod. Those speakers attached are 400 watt motorcycle speakers. Yes they are quite loud. I originally wanted adjustable ride height, but I just couldn't make that work so I went with a 3 inch clearance so I can handle speed bumps. I finally started getting the electronics sorted out, first using LED strip lighting. And here is another stack, looking better this time.... I decided to attach the hemispheres simply because I had nowhere else to put them. Recently, I've been working on the electronics and I have been casting oil seals using PTflex85, but the 4 lb kit ended up only being enough for 48 seals which is rather frustrating.
  5. This is apparently the first photograph of my progress - March 2016. The rings were routed from 3/4" MDF and the vertical supports are polar cut to size. The dome was the product of my very first attempt at fiberglassing, so it came out fairly rough. I am still touching it up quite a bit to be made presentable. In April 2016 I cobbled together a frame to start the shoulders with the help of a laser cutter at the local hackerspace. I also cut out the gunboxes and constructed the neck blocks from poplar and ball bearings. Here is close up detail of my dome rotation / eyestalk mechanism. I may change this later to be controlled by servos. And a closeup of the very poor quality dome: In September 2016 I finally started construction on the shoulders. These were a pain in the butt to get together and they are still giving me trouble since I am trying to get them smooth enough for a fiberglass mold. On the bright side though, they make an excellent, inescapable baby cage. A bit of the clamping process: Masking off areas for expanding foam filler: Despite masking, it still got everywhere, but easily removed with light scraping from a chisel: While working on the shoulders, I developed a way to properly center 1/4" bolts inside my fillable christmas ornaments. I first tried using bondo and expanding foam, but that didn't work whatsoever. What finall worked was scratching the inside of the hemisphere very well and then using fiberglass resin with not quite enough catalyst. Too much catalyst resulted in excessive heat and the hemisphere melting. I would leave them out in the sun and they would cure without difficulty. I also finally started working on the skirt structure. I beveled the interior edges so that the skirt panels would fit flush. I may eventually end up fiberglassing the skirt as well, but right now it works fairly well. I finally finished the neck rings in October 2016 with heronrib equivalent from Home Depot, diamond grid BBQ tops and black stretchy fabric that I can see out of, but other people cannot see in.
  6. I stumbled upon Dalek building in January 2016 and used it as a stress relief and escape from the demands of being a new parent. I had originally hoped to get the Dalek together to take to Alamo City Comic Con in October 2016, but it just wasn't ready at that time. I have since been working diligently to get my Ironside dalek together for the next convention in late May 2017. I have been lurking on this site for quite a while, but I finally decided to start documenting my progress. So far it has been a wonderful process and I have learned so many new things along the way, like working with fiberglass, welding, painting, sculptng, and so much more. Things that still need to be completed: 1. fiberglass mold of shoulders 2. assemble light cages 3. construct cowl 4. fiberglass mold of cowl 5. obtain moflash lenses or suitable substitute 6. construct shoulder slats 7. construct arms I'll come back in a bit and update this with pictures
  • Recent Status Updates

    • chris harper

      Saturday spent fixing first bit of 6mm bendy mdf to my shoulder frame, I had a couple of clamps but a friend lent me about 8 and needed every one. My son in law loaned me his multi tool which cut like a dream, however, he needs it for work so had to give it back so went to Wickes and bought one for £25, a bit cheaper than his top of the range model but it still does a great job. Have fibre glassed my dome plug after waxing the he'll out of it, fingers crossed it will come off ok.
      · 1 reply
    • chris harper

      My dalek will have a name, talking to my friend about old films, and we talked about the  Eiger Sanction, and came up with the name Hemlock, so now my half finished skirt, nearly fully sanded dome plug and shoulder frame has a name...Hemlock
      · 0 replies
    • DathandsomeDalek

      Hello! I joined a few days ago and I'm trying to see how this site works
      · 1 reply
    • project one

      Waiting for hemispheres.
      · 3 replies
    • John  »  monkeytennis

      Many thanks for donating, to support the cost of Forum hosting. Very much appreciated.
      · 0 replies