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.

Stephen R

Stephen's Dalek

17 posts in this topic

Hi Everyone!

Well as promised here we go with my attempt at exterminating my part of Southern California!  I have been working on my Dalek for a few months now. I didn't post anything earlier because i didn't want to be an "unfinished" build diary and just leave everyone hanging.  I needed to make sure I was committed to the build and will have a completed project when done.  Now that I am into it and obsessed- my wife thinks I need to be committed!  I apologize if the pics are not correct. I tried to resize them before uploading so let me know if they are ok. 

 

 I'm making the skeleton out of plywood.  MDF is hard to locate in my area. 

skirt 01.jpg

 

so in my excitement to finally start my build- I didn't realize I needed 2 sheets to make both the top and bottom of the skirt! I cut the top out of the middle of the bottom and inadvertently found myself making a support less skirt! lol. Read the book Steve! ugh.  

skirt 02.jpg

 

Angles!  This thing has angles on the top and bottom!  and they are not normal so you can't just cut them so the panels lay the way they should!  I tried using files, sanding blocks, a disk sander in my electric drill- what a job I did! I should have been a butcher- they were a mess! hahaha.  so i came up with this thing.  it is a 1" x 2" stick with sand paper I contact cemented on to it so I could sand one surface while the other surface was used as a guide.  You get the idea of how it is used by the picture I have of me using it on my shoulder.  I am sanding the bottom of the shoulder with the stick rubbing on the top of the shoulder (not sanding anything there) as a guide.  Then I flip the tool over and sand the top angle with the bottom rubbing as the guide.  It seems to work. :)

 

tool 01.jpg    20170107_145041.jpg

 

 

I bought some hard board from Lowe's here in California to do the skinning of the skirt and shoulders.  I'm using liquid nails as the adhesive and I have a little air brad nailer I bought from Harbor Freight for nailing the skins on.  

skirt 03.jpg  skirt 04.jpg  skirt 04a.jpgskirt 05.jpg

 

I don't have any pictures of my cutting the hole in the top of the skirt. I waited until I had the hole cut in the bottom of the shoulders then I just traced it on top of the skirt and cut.

 

Here is a picture of the wife in the skirt with my resident inspector Coco, checking out my handy work. I need to keep her interested in the build since my Dalek is slowly taking over the house and income, lol.  

I will use the liquid nails and strips or hardboard method I have seen to seal the seams since I am not up on fiber glassing just yet.  I did some when I was a kid- but I did talk the wife into helping me with the dome when it comes time.  She has had some experience with fiber glass.

 

skirt 06.jpg

 

This is Fun!

 

3

Share this post


Link to post
Share on other sites

Howdy Everyone! 

 

I know this isn't correct for this one- but I can't resist.  I was just fascinated with the claw version of the arm- so I went and made one.

People at work got tired of me chasing them with it. :)

This is made out of .750  or 3/4 mdf- which I was able to find- and then some 1" aluminum square tube I cut to length then cut one of the ends off to form a channel. (it pays to work at a manufacturing plant that has a machine shop- I go play a little when the machinists leave for the day)  The threaded part is a small piece of threaded tube used in lamps- got it from Lowe's in the lighting section. The bolt in the center is a 5/16 sized carriage bolt and some 1 1/2 " diameter fender washers.  I ground a flat on the bottom of the bolt so I can drill a hole and run the actuating wire thru it. I am thinking of using a hand brake cable from a bicycle that was mentioned in one of the build diaries that they were using for the Eye up and down movement. :) I think that it would be able to actuate the claw and is flexible so it will move inside of the arm.

 

 5892495400abc_claw01.thumb.jpg.35159d325c12e4eba3f2b88ad4b46a11.jpg5892496057436_claw02.thumb.jpg.d449c4178d4ec6dd32a0a0eeaba94bb4.jpg  

 

I still have to take the claw apart- finish sand on a few spots- drill a hole, then prime and paint silver.  

 

3

Share this post


Link to post
Share on other sites

Hello Everyone!

 

I'm finally getting some time to post a few pictures. :)  I finally got all the parts in to finish the voice modulator pcb!  The final missing resistor came in last Friday.

 

 5898dd948a6ef_pcb01.thumb.jpg.cc1ef5cf86001eecb8241378438c8d39.jpg5898de4c5f99e_pcb02.thumb.jpg.b0408cc64a6e049c43a03c51b21d184e.jpg5898dd9d7dc3f_pcb03.thumb.jpg.8d4b3de9d04d4f1d25eb05c923ee07cf.jpg 

 

I bought the amplifier on amazon and I am just waiting for my little battery to come in before I can play with it. :)

 

 

 

1

Share this post


Link to post
Share on other sites

Hey Stephen, looks like you've done loads in a short space of time. It's going to be a good one. Keep going

2

Share this post


Link to post
Share on other sites

Thanks Simon!  some of the pics are actually over a few weeks span. I just waited till I had enough to start posting them. :)

We are in the middle of a rain spell here in Southern California so I can only work on the beast during the week end right now for the big stuff.  The small stuff I tinker with when I get home from work.

 

So I was playing with the Voice Modulator last night.  I bought a cheap headset with microphone and followed the videos that CDNGOOSE has posted on how to balance it and make it work. I had to go sit out in the car and plug all my stuff into the cigarette lighter to make it work, lol.  My battery comes in in a week so I have to work in the car right now for the 12v power supply, lol.  I got it to work some, but it just wasn't 100%.  I went back in the house and took a closer look at my build.  I noticed that the longer IC didnt look right in the socket so I pulled it out.  It looked like it had been installed by a cross-eyed drunk!  The little legs were all bent wrong and some were not even in the socket!  I said it looked like a centipede that had play a game of twister and lost! (left foot blue, right hand red) lol.  So I straightened the legs out carefully and re-inserted the IC into the socket.  I ran out of time so I will try this again tonight.  

1

Share this post


Link to post
Share on other sites

Good Morning all!

Well the voice modulator worked much better! Tip- it helps to have the parts installed correctly and not all wonky! lol

I wasn't sure if it was good until I played a recording for my wife I made and she asked who that was and if I took it off the TV. :)  So, don't over think your outcome if you make one of these- lol. Making the MK5 is not hard if you know how to solder and have a basic knowledge of the components.  I will post a video of it later once I upgrade my speakers and can speak a full sentence with out choking and going into "Exterminator" mode. 

So- here are some pics i took of the shoulder build.

I'm making the frame from 1/2 inch ply as well, used my "special sanding stick" to get the angles to match so the hardboard lays flat when it is attached.

589cb25082b7d_shoulder01.thumb.jpg.2b1156d325040574788ce7f68442c271.jpg589cb262029be_shoulder02.thumb.jpg.da156bcce11cf5c88fe19f681a7b563c.jpg589cb26651ef3_shoulder03.thumb.jpg.395451dcc96dfa4760012db0c96f3d0e.jpg589cb26a7e1af_shoulder04.thumb.jpg.656eb8b5b58ab84e35c4b4438e0b155f.jpg589cb2715b5b7_shoulder05.thumb.jpg.87029a0ee8650db93feb0dfb1fb3fa8a.jpg  

 

I'm using Liquid Nails adhesive and my little air brad nailer to attach the hard board.

 

589cb27aab0b8_shoulder06.thumb.jpg.a178641a5fa3f0634cac4eac3af16deb.jpg589cb2818d3b9_shoulder08.thumb.jpg.8c11956b9715fb57ca53177cb2f47632.jpg 

3

Share this post


Link to post
Share on other sites

Hi it looks like it's coming along nicely keep up the good work :)

2

Share this post


Link to post
Share on other sites

Hi Tk7273- thank you! I'm having a blast making this. 

0

Share this post


Link to post
Share on other sites

Ok, now some pictures of the dreaded gun box!  oh and before I forget- I soaked the hard board for the shoulders in the shower off and on for about 1/2 hour to get it soft enough to bend.  I'd soak it, then go watch tv then go back and soak it, etc.  I didn't use the bath tub to do a full soak since the wife would have gone ballistic for soaking wood in her tub, lol.  Those of you that are married know about personal survival sometimes!  The wife is tolerant up to a point!  I then clamped it like crazy and let it dry for 2 days to keep the shape. It worked really well.  This hard board is the 3/16 thickness you get at Lowe's here in the USA. 

 

On to the gun box with no plans!  So I studied Adam's build and his pictures and the drawings I could find in the plans from here as well as everyone else's build diary and I came up with a cardboard trial.

 

589e23365d802_gunbox01.thumb.jpg.968585628b4c103e6f27eff37d0db5d4.jpg  589e2345c8127_gunbox02.thumb.jpg.92e9e18338345311e72e548f570bcb2a.jpg

 

I looked more at Adam's build and trimmed off a whole lot of cardboard and just started cutting and playing with it.  I came up with the following final configuration.

 

589e23d7f1cbe_gunbox03.thumb.jpg.b08f372c308ac98faafb6cc5c5e69a87.jpg  589e23dea69c2_gunbox04.thumb.jpg.50ec42e67065fc6edf261ebd59e5bde3.jpg

 

Now, there was a whole lot of experimenting with making the front pieces before I came up with the above. 

 

I tried using a hole saw to cut the hole for the gazing ball (which I bought off amazon) but it was too small so I tried to make the hole larger with my sanding tool.  

As you can see the right hole looks like a critter chewed on it! ugh.  So I made a little jig for my router to make the hole- it came out perfect! And it was the right size.

I had read in one of the diaries a builder ( and I apologize for not remembering his name. I will find it and give him credit) of how he made a tool from a Xmas ornament to make the correct chamfer to fit the ball.  I did the same thing and put it in my hand drill to sand the chamfer.  As you can see it worked great!  Tip- go slow with the drill!  I turned it too fast and burned the sandpaper! lol. It gave a nice dark burnt wood burnish to the inside of the hole, ooops.   So the gazing ball now sits in its little hole all nice and snug.  I made the 2 back holding pieces as well and that was about all the life there was in the homemade sanding tool. 

 

589e244985b1c_tool03.thumb.jpg.726743c036a05ee7948263e0113916e9.jpg  589e2472260f0_tool03a.thumb.jpg.7eb7a1cee5ba9d6f1a7050d6bfb7c9a5.jpg  589e247c2a03f_tool04.thumb.jpg.d4fd783bf77d84710468cc6132429735.jpg  

 

So- following Adam's alignment procedure- I attached the gun box using "L" brackets and screws in the hopes they will be right, lol. 

 

 

589e263d8b65b_gunbox06.thumb.jpg.a16e27e51525d81c90fc66769f724369.jpg  589e2640f14de_gunbox07.thumb.jpg.b867e2600a25b10eaa7b74ad8a1ce511.jpg  

 

Here are some pics of the gun box with the gazing ball retainer and screws set.  I have removed the gun box from the frame and am currently sanding it to get it ready for Bondo filling of chips and screw heads and primer for painting.  After I took off the gun box- I fitted the hard board that I posted previously above and attached. it.  Once I get the gun box to the point of being ready- I will cut the holes in the shoulder board and fit it through for final attachment.

 

589e264c33cde_gunbox09.thumb.jpg.dec8a6f5ccb10f27b9274ae211fbd1fe.jpg  589e2645b9e62_gunbox08.thumb.jpg.2166b15f157bbc4267d8a62553e4eed8.jpg  589e2786b914b_shoulder06.thumb.jpg.8dac3bcb7b8c4ba2e94206b045b56930.jpg

 

Hope you all are doing well with your builds!

1

Share this post


Link to post
Share on other sites

Good Morning everyone.

I'm doing a few odds and ends now on the Dalek.  I bought an adapter to make my headset go from stereo to mono for the microphone for the MK5 voice modulator. For those of you in the USA - I got it from Cable Wholesale. It is part number 30S1-04300 and cost a whole .38 cents. 

30s1-04300_01_th.jpg.59952c51027c0849768be0066cf46031.jpg

 

I also outlined the gun box holes in the shoulders and cut them out.  Boy- was I off! lol.  I'm going to have to do some filling once I get it mounted permanently! lol. This really is a fun project!

58a47b6141939_shoulderwgunbox01.thumb.jpg.8b6bb4fad237394b58f2a23a9d33a02f.jpg   58a47b6a38970_shoulderwgunbox02.thumb.jpg.89fd020c6fac4ca8cecdf5c9cfd21462.jpg

 

More to come!

1

Share this post


Link to post
Share on other sites

Nothing like the smell of bondo in the morning. Nice work. 

Edited by Simon James
Typo
2

Share this post


Link to post
Share on other sites

lol- I know, right Simon!  I lucked out and the wife was out when I mixed the stuff up. I forgot how aromatic the stuff is from my teenage years when I used it on my cars.  I let it sit outside for a few hours before I brought the gun box back into the house, lol.  I filled the screw holes and will sand the box up before I mount it permanent in the shoulders. 

1

Share this post


Link to post
Share on other sites

Good Morning my friends! 

Not too much going on- just filling and sanding and you all know how much fun that is! :)  I dragged all the pieces together and did a quick stack up just for inspiration- and boy I gotta tell you, if you ever get discouraged on your build or if you think it is taking for ever- just put it all together and stand back!  You will get fired up again to do more work!  Enjoy the day and make something!

 

58ac582a3db16_stackup01.thumb.jpg.e52a6d1af11aab57d8ba3112ea0babb8.jpg 

 

2

Share this post


Link to post
Share on other sites

Looking good Stephen. Have you cut your neck rings out fully yet?

2

Share this post


Link to post
Share on other sites

Hi Simon- Thanks :)

as for the neck rings- no not yet. I cut the OD and just ran a small cut around the inside so I have an idea where to drill my 3 rod guide holes.  I will work on them this week end.

I'm thinking I will finish drilling the holes then cut the 45° angle on the outside then finish the ID cut out.  I've been filling and sanding the mistakes on the gunbox, lol and gluing strips into the skirt section in place of fiber glassing it. Your build is looking great btw! 

 

58adf4cea9d35_neckring01.thumb.jpg.7d26575c03ea4faa94ed46092799c07b.jpg

1

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!


Register a new account

Sign in

Already have an account? Sign in here.


Sign In Now