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Started a few years ago with downloaded MK-III plans and the handbook. I have a lot of tools but there are a few I will not do without a second time!
I made a base out of 1in plywood for strength but the front section wound up too long and narrow. I'm not going to fill the gaps as the skirt is sturdy and the error is underneath and hidden. To save weight and money I tried using 0.25in plywood for the panels but everything warped so badly I had to completely redo the panels with thicker plywood (I hate using MDF). The truss I built from 2x4 lumber helped greatly in centering the top of the skirt and getting the new panels on. The new panels still warped some but that's due to my workshop being an open carport! The cheapest hemispheres I could find were 4inch foam balls I could paint halves to look like the show. These are still $4 US @! The panels are staying smooth for now.
The Gunbox was tricky as the plans were not specific about it's dimensions nor where to place it exactly. I finally just made a rectangular box and attached it where I thought it looked good. For the arm hole balls, I drilled a 3.5inch hole and beveled the inside edges. The backplates worked perfectly but are hard to access to get the nuts on the bolts.
The skin of the Shoulders came out well. I used thick paper to wrap around the curves and not crumple. With everything covered by paper, I coated the paper with polyurethane. This stiffened the paper so I could fiberglass over with just two layers. Then something fell on the Dalek and chipped the Gunbox edge! Bondo to the rescue.
The Neck Rings came out okay but I could only rout a 45 degree edge down 0.5inch, so my rings look like the Imperial ones.
I built a Lazy Susan type head swivel out of two plates of 0.5inch plywood with matching routed grooves. I filled the grooves with marbles as a type of bearing. I later found a much better Lazy Susan from a Science Surplus catalog and will use that next time.
I'm on my fourth Dome attempt. The first I measured wrong on the template. The next few times I tried different modeling methods but none worked well enough. My last try was a beach ball I covered in paper machie. The idea was basically sound but the ball deflated overnight and I had to add to the edge to make it clear the neck struts. I have this dome to the point where I am fitting the eyestalk pivot.
I have to redo the pivot as the first one came loose in my drill press and the eyestalk hole became off center. I want the hole through the pivot as I am planning to put a web camera in the eye of the Dalek.
One thing I really need next time is a workbench. For this build, I used the base of the Dalek as a workbench.
I'm going to complete this build but use my experience to build a much nicer one next time!
Going out with a funny story. We have salespeople coming door to door, selling security systems. I like to lead out to the Dalek and describe how I'm going to make it an automated security system with facial recognition and more! Their eyes get big and leave vowing not to ever bother my house! The security sign on the lawn will state "forget the owner, beware the Dalek!"
To be honest, they look fantastic, despite the small in-consistences. You're a perfectionist, and that comes through very
strongly in your work and research. As already mentioned, and as we all know, when considering the original props, they were far from perfect and uniform;
hand building creates that unique difference. Keep up the good work, I'm enjoying all the updates on your project.