Star Trek Kelvin Phaser Project

Well if one phaser project on the workbench is good, two must be better, right? Actually, my TOS Phaser Project is one hold for a few days until I can get some of the dimensions confirmed. In the meantime, I've started modeling up the Kelvin Phaser from J.J. Abram's 2009 Star Trek. I know it was never seen on screen, but it's such a cool design I just had to take a crack at it. One of the coolest things is the rough, almost crude look to the cast metal surfaces. That'll be fun to duplicate (easier than making the surfaces perfect, that's for sure!).

Working from auction photos of the prop, I've first drawn it in 2D and then used those drawings to build a virtual 3D Cg model in Rhino. This will then be used to mill out the patterns on the CNC.

Here are some work-in-progress renderings of the Rhino model. There are still a few details to finish.

I like the look to this one. Really looking forward to seeing what you do.

I like this. How come if they could update the TOS phaser so well for he Kevin crew, the Enterprise folks had that stupid ray-gun looking thing?

Angelus Lupus said:

---

I like this. How come if they could update the TOS phaser so well for he Kevin crew, the Enterprise folks had that stupid ray-gun looking thing?

I agree, they used the wrong props for each crew. I wouldn't have minded if the official phaser had been some obscure background prop and the barely-seen Kelvin phaser had been used for the Enterprise crew. Same with the communicators, for that matter...

Here are the main parts for the phaser milled out of 40 pound HDU and cleaned up. The knurled pistol grip and "milk jug" on the bottom will be turned on the metal lathe.

Very nice!

It's a shame this version of the phaser didn't get more on-screen time. I'm not a huge fan of the TOS-style props, but that phaser is pretty cool.

Sean

That is pretty cool. I didn't even know that it had existed.

Very Cool!!!

Beautiful work, Dave!

Cant wait to see the finished product.

The is one of first HDU models I have seen. Wow. What kind tools did you use to obtain such a uniform shape?

Thanks.

Gordon

Ya know, im not really a phaser kind if guy, but my goodness this thing is beautiful....

Thanks guys! The more I work on the Kelvin Phaser, the more I like it. The design is kind of clunky, and un-refined. In many ways, very un-Trek. But it's still really cool!

The parts for the body are mostly finished and just about ready for molding. I used a very thick water based primer, sprayed on in a heavy texture, then sanded down a little. But there are still areas that are rough and uneven. It should give the sort of crude cast metal look that the original had.












The milk can shaped protrusion on the bottom was turned out of acrylic rod then cast. The casting was then cut to the appropriate angle to fit into the bottom plate.

Gordon, To answer your question, the 40 pound HDU (High Denisity Urethane) that I'm using can be cut and shaped just like wood. It's about the density of mahogany. The patterns were milled out on a CNC router that I designed and built. Then fine details were added with chisels and scribes. Pretty much like working with a nice hardwood, except no wood grain.

Here's a photo of my 3 axis CNC Router.

Here are the RTV molds with the first set of pressure cast resin parts.

Nice machine! I would love to see your pressure casting rig as well. The phaser looks great too!

Thanks! The pressure casting rig is nothing fancy. Just a chamber made from a piece of 10 inch square, 1/4 inch thick wall steel pipe with 1/4 inch plate welded to each end. The door closes from the inside so it can't blow out. Simple, reliable.

I would like to have one

bundy said:

---

I would like to have one

Well, stay tuned!

Here's the first bunch of castings.

sahhhhhh-weeeeeeeeet!

Dave do you have a price on these yet

Jarvis B said:

---

Dave do you have a price on these yet

Not yet, I haven't decided if I'm going to sell kits, or only offer them as completed painted collectibles. I need to assemble and paint a couple first see how long it takes. Plus I still have to make, mold and cast the handles and a couple of little detail parts.

Stay Tuned!

Very nice!

DaveG said:

---

Not yet, I haven't decided if I'm going to sell kits, or only offer them as completed painted collectibles. I need to assemble and paint a couple first see how long it takes. Plus I still have to make, mold and cast the handles and a couple of little detail parts.

Stay Tuned!

Oh, please do kits. I love the body of this design, but desperately want to make a custom handle and trigger for it.

Dave, I'd be interested in a 'completed' version.