Shaw
Well-Known Member
This is a project that I've spent a ton of time and effort researching. I started by drawing up an early version of my plans for this model back in 2007, and followed it up with two study models (here and here) at two-thirds scale to help refine my plans (and improve my model building abilities). Originally I had wanted to build this model out of the same materials as the original (which was mostly made out of kiln-dried sugar pine), but I don't have any of the equipment or experience to deal in wood, so I'll stick with what I know I can do.
For a bit of history on the original model, you can check out this page I put together.
Where to start?
I decided that I'd begin with the secondary hull. The series of images below show the steps I've taken to build a master (more of a pre-master).
It started with cutting out pieces of foamcore board and building a base structure. Because this will be the master for both sides, I've included holes and alignment channels for both sides for the nacelle support pylons to slide into. It is easier to build the parts with both holes and fill in the extra later than to build it without any and add them later or build two of these. I'll be doing this exact same thing when I build the inboard nacelle master so I only have to build it once.
Next I put blocks of styrofoam in to the openings and used a hot wire to cut them to the general shapes I needed. And then with them glued into place, I used a template of the secondary hull shape to lay out a surface made of hydrocal. I let that dry/cure and then filled in any gaps that showed up.
That is about where I'm at right now. This isn't all that different from how I made my primary hull for my one-sixth studio scale 11 foot TOS Enterprise (here), but I figured I'd show how these same steps could also be used to make a little more complex shape... so here is the start of the (pre-)master to the secondary hull of my Phase II Enterprise kit.
It was made the exact same way, just requiring a different template for the shape and the alignment channels for the nacelle support pylons are at a different angle. And this is them together...
And no, this model is not going to become a kit... nor could it's parts be used to convert the Round 2 1/350 TOS Enterprise (which is smaller than this model by more than an inch... 32.4 inches compared to 33.75 inches).
So now I'm waiting a while for the hydrocal to completely dry/cure before I add on a surface that I can work to a smoother finish. When I'm all done, I'll make a mold and cast two parts. Hopefully this won't take as long as my Phase II Enterprise to build (which was two years) because I have most of the research already done.
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