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lstronghill

Lstronghill's Double Dalek Project

32 posts in this topic

After plenty of research and re-watching of Dr Who we have decided on building two daleks...might as well build one for myself! Jr's will be a Shawcraft Mk 3 and mine will be a Shawcraft Mk 2...I already have friends shaking their head at me wanting to know if I'm right in the head...definitely not! I wanted to do a pink dalek and was so excited then found out about Candi. Hurray and a bummer. I have a couple more colour ideas but that is such a long way off I'll deal with it later. As for Jr at the moment he wants the General Lee hemi orange with Tardis blue hemis...remember he's 8.

A local dalek builder/owner has taken us under his wing to help us with the builds and use his shop after finding out that we were going to build in our apartment. Between schedules we will have Saturdays and school holidays to work on the builds. As an added bonus Jr needs to earn weekly shop time and has a chart to track his behaviour/progress. He will have plenty to do if he does not earn his 7 hours of weekly shop time while I get further ahead with my build...creative parenting!

Day 1 - Sept 19, 2015 - Base frame

We had pre purchased two 4x8 sheets of 18mm plywood which was already at the shop allowing today to be a complete build day. It was also an introduction to shop safety as Jr had been in a shop before but only after clean up and had never used tools before.

Step one - We converted all measurements from inches to millimeters as some did not make sense. What is 8.1 or 6.8 inches?

Step two - Drew the measurements for the outside of the skirt and cut it out. Then drew the lines for the inside of the base and cut out. For the second base we drew all lines (inside and out) BEFORE cutting which made it much easier.

Step three was sanding.

Step four assembly. And finished base frames!

Two base frames done in seven hours!

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Until the next shop time...

Edited by lstronghill
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HI & congrats on starting, from Cowtown AB.

Point in hand, most of us use decimal inches (& the plans - Take a good look at your rule or tape measure to see if it supports that convention), if you are of a certain generation or younger. ;)

Edited by Ferrain
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well done ;)

as a second dalek i want to made a Mk3 ... i'm going to follow this Wip ;)

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HI & congrats on starting, from Cowtown AB.

Point in hand, most of us use decimal inches (& the plans - Take a good look at your rule or tape measure to see if it supports that convention), if you are of a certain generation or younger. ;)

Ferrain,

I did like your pre-edited post. Being in my early 40's I was part of that confused generation that was taught some of both metric/imperial while one was phasing out the other. It just means that I deal with a bit of both (inches/feet, kms, pounds/ounces) which doesn't really help. I enjoy formulas and long math so have been in heaven working out the numbers anyways. :D Thanks for the tip on the tape measure!

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After several setbacks and comic cons we finally made it back to the shop.

Jr earning shop time has made a huge impact with his attitude and outlook. After some massive tantrums/attitude which resulting in deducting shop time he ended up earning 2 1/2 hours over 3 weeks and not being able to trundle at a local con. Lesson learned!

Day 2 - Oct 24, 2015 - Shoulders and neck frame

One of the first things we figured out is that we should have traced the outside top of the skirt frame to make the shoulder base to get the correct angles. The over all dimensions are 28.5" x 25". Measure many times BEFORE cutting. Jr's was fine but mine was 28" x 25".

Using left over plywood from the base we used a protractor with the pencil extended way out to make the circles for the inside of the shoulders and neck. My method was to use a string wrapped around a pencil and kept taught. It's never failed me before. This is where we had our first run in with three strong personalities in a small shop all having a different method to end up with the same result. We all survived intact but a coffee did get spilled on my frame...the tea drinker now has a coffee smelling dalek. :-)

The best part of making two daleks is figuring everything out for one then tracing it for the other.

The struts were cut at 13" to compensate for the 1" board height for a total of 14".

We miscalculated the circles for the neck and shoulders and ended up needing to take another 1" off the diameter. Better that than being to small. Kids make a good counter weight...:-)

Total shop time 5 hours.

What we did notice while taking the photo of Jr inside his completed dalek frame is that he is small enough to walk in it for awhile. This means that I can use his wheelchair and will readdress his reserved seating later.

Until the next shop day...

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Edited by lstronghill
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nice work ;)

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Love this one.... definitely going to keep following this..... :)

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October 31, 2015 - Skirt panels

No trick or treating here. Jr opted for dalek work instead.

This was and continues to be tedious work. Jr finally understands how important being accurate is.

Step 1 - Jr measured out all panels based on the pattern layout (below).

Step 2 - We are using hand tools as much as possible which really made this part frustrating for me...cutting all the panels by hand with an exacto knife. I was dying to use the table saw! Needless to say the panels are rough cut.

Step 3 - Square off panel measurements to cut off excess. (still need to cut off the excess)

Step 4 - Measurement/cut for the final panel shape. (yet to do)

Shop hours - 4 hours so far

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Sorry for the late progress reports...hopefully I can still decipher my notes...

Nov 14, 2015 - 3 hours - Panels to skirt

Started with panel 6 to attach to the skirt. We had problems with the final panels when following the panels dimensions and ended up making custom panels based on what we had using the following method. Line uncut panel 6 even with the bottom corners of the skirt. Mark the top corners of the frame on the MDF. Knife cut the line from widest to narrowest for best results. Glue the cut panel to the frame matching the bottom of the frame to the bottom of the panel. Nail into place. Do the same with panels 4. Lay panel 1 against the frame like panels 6 & 4. The difference is these panels will have a twist to them. Continue with panels 2, 5 & 3. Sealed the inside of the seams with heavy fabric strips and resin.

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Dec 12, 2015 - Shoulder Wrap

Tape two pieces of bristol board together and wrap around frame to make a custom wrap. Do the same for the back of the shoulders. Trace onto MDF. We ended up tracing the bristol board off another dalek and customizing it to fit ours.

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Dec 22, 2015 - Shoulder Wrap con't

Cut the MDF wrap. This was a three person job next. One used a heat gun on MDF to make it pliable and wrap around the shoulder frame. Another held the wrap in place while the third person tacked nails into the top and bottom of the wrap and used clamps to help hold the wrap in place. Cut the gun box holes. Cover the top and bottom seams with painters tape and glue inside of wrap.

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It’s been awhile since I gave an update on our build. Luckily I have a log book that has the details. J

January 9, 2016 Gun box

We cut three boards 49cms for the top and sides. Two 5”x 4” pieces were cut for the ends.

Assemble the box.

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Find the centre line then mark either side 3 ½”. On a table saw cut through the front of the box. Cut the flip for other cut. Chisel out the middle trough for clean cut. Remember to make the saw depth cuts longer on the bottom of your gun box as it sits on an angle.

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On what will be the top piece (the front when in the dalek) were measured in 6” on either side and marked. Make an X corner to corner from the 6” line to the end of the board for both right and left side. Drill the centre of the X then cut a 3 5/8” circle. Use a router to cut a 45 degree angle on the side to help secure the gun joints.

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Jan 23, 2016 Rings

The MDF was cut into 24 ½” x 49 “at Home Depot to fit in the car.

The boards were then marked as 24” x 24” (inside diameter of 20”) on one sheet.

23.5” x 23.5” outside diameter (inside diameter of 19.5”)

23” x 23” outside diameter (inside diameter of 19”)

Glued three dowels together to form a triangle (template) then traced the shape on the rings for space holders.

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January 31, 2016 Rings con’t

Drilled triangle holes in the rings.

Drilled pilot holes in the rings to router out the ring insides.

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February 6, 2016 Rings con’t

Routered outside rings for leveled edge. Cut out the inside of the rings with a jigsaw.

Cut dowels to 9 1/2” and spacers 2 ¼” for between rings. Place dowels in first (single) hole then add other (double) dowels. Start adding rings to see how it fits and looks.

Added bonus for the day…we killed a router!

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February 13, 2016 Gun box

Measure 3/4 “on the diagonal lines and drill screws in slightly.

Put inserts for the ball joint in gun box to drill holes.

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February 27, 2016 Middle section

Sanded middle section and applied the first coat of primer.

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Very nice. Really been enjoying this build! Keep up the great work.

- Dolan

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Not a lot going on except sanding, putty, paint and repeat.

March 6, 2016 - skirt

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March 9, 2016 - Hemis arrived!

March 13-15, 2016 - Skirt and shoulders

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More sanding, priming, putty and repeat.

 

April 10, 2016 - skirt and shoulders

   sanding Shoulders.jpgprimer layer 1.jpgskirt primer layer 1.jpg

 

May 21, 2016 - cutting gun box holes, sanding, puttying and fiberglass

gun box holes.jpggun boxes in.jpgfiberglass gun boxes.jpgmixing putty.jpgputty.jpg

More sanding, puttying, and priming has been happening since. My arms are done with this stage...literally...doctor's orders to take it easy.

 

As a surprise a friend gave me a dome and an eye over the weekend! WOO-HOO! HUGS!!

 

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This was really interesting and gave me great ideas for my dalek i hope you succeed with your double dalek

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Just keep a slow and steady pace. Remember if a 9 year old can do this anybody can!

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