NSD Cowl 1.0.0

Here is a set of models for creating an NSD cowl. Jbourd was kind enough to gift me with a 3d model of a complete Dalek dome and cruel enough to ask if I could separate out the cowl. It took a while but I managed to remove the dome and leave the cowl intact. Of course it is far to big to fit on my build platform. So I tried cutting it in half vertically. Each piece could only fit my build space in a few orientations. And due to the size and nature of the parts, they all warped beyond use. I wasted nearly a kg of filament on failed attempts. I decided to split it into quarters. This allowed for smaller parts which would fit flat and any warp would be to the thickness. Thought I had it nailed, but the thickness was warped enough so that the towards the back of the cowl the opening was too small to fit the eyestalk pivot. So I added a shim to compensate.

I have been using 3d Builder which is included with Windows 10. It has issues. For whatever reason I was able to separate out and save three out of four quarter pieces but the fourth would not save no matter what I did. So instead I used Replicator to mirror the pieces along the X-axis. That is why only right side parts are included. You have to use your build software to mirror them for the left side parts.

I've included the full cowl model in case you want to slice and dice it on your own. I've included the shim I used and a long peg to use with it. I suggest building out the four main parts and see if you need it.

Also the bottom parts had an issue with one corner pulling loose from the build plate and warping the holes. So I put a throw away block next to that corner to hold it down.

I printed everything at 10% fill .2mm thickness. Use full support and raft for the main pieces but not pegs and shim.

One thing I did not expect but really like is that in producing the curves, the printer leaves a pattern which is similar to wood grain. This is another reason why I included parts for only one side. By mirroring the parts the grain pattern is symmetrical.

Here's some pics. You can see the grain effect.

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