Star Trek Kelvin Phaser Project

DaveG · Mar 1, 2011

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.

MooCriket · Mar 2, 2011

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

Angelus Lupus · Mar 2, 2011

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?

WinstonWolf359 · Mar 2, 2011

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...

DaveG · Mar 6, 2011

Milled Parts

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.

masterjedi322 · Mar 6, 2011

Very nice! :thumbsup

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

GBRyker61 · Mar 11, 2011

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

MooCriket · Mar 11, 2011

Very Cool!!!

brandomack · Mar 11, 2011

Beautiful work, Dave!

Cant wait to see the finished product.

Harada357 · Mar 11, 2011

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

Thanks.

Gordon

kursosawa · Mar 11, 2011

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

DaveG · Mar 11, 2011

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.

DaveG · Mar 11, 2011

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.

DaveG · Mar 15, 2011

Molds Done

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

DrewSmith007 · Mar 15, 2011

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

DaveG · Mar 15, 2011

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.

bundy · Mar 17, 2011

I would like to have one

DaveG · Mar 17, 2011

bundy said:
I would like to have one

Well, stay tuned! :thumbsup

DaveG · Mar 18, 2011

An Armory in the Making

Here's the first bunch of castings.

DrMcoy · Mar 22, 2011

sahhhhhh-weeeeeeeeet!

Star Trek Kelvin Phaser Project

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