11th Doctor's Sonic Scratch Build

Prizrak5150

New Member
Alright, Mr. Robatto is very readily nearing his 250 sonic mark and I doubt I'll have enough money in time to get the 250th slot, so I thought hey, why not build my own from scratch? Only I'm poor... So this'll take a while, maybe.

I've already compiled an embarrassing amount of pictures of sonics in various stages of complete ion and put together this exploded view and parts list.
IMG_2353.JPG

There's some stuff I don't have on my parts list because I either already have the materials (leather, foam, wiring, etc.) or I simply don't know how I am going to do a certain component (mainly the white resin handle; although, getting the tip to the aluminum slider right seems like it'll be tricky too).

Shoutout to SanHolo80 who has already been a tremendous help with clearing up some questions about the sliding mechanism and various measurements. Thank you for your help.

This project is gonna take a long time. Mainly because I'm in college so funds are at an all time low, but also because there's bound to be lots of failures and cursing and rage-quitting. I expect this project to end probably sometime in March. I know if I really really wanted to, I could probably get it done by February, but im on a budget and have limited resources. I'm probably going to have to use the metal shop at my college for most stuff in fact.

Anyways, I'm about to make a run to the hardware store to see if I can get the main brass pipe and the components for the sliding mechanism for under twenty dollars. If you stick with me for these next couple of months I'm sure it will be lots of fun for all of us.
 
Okay, so I went to the hardware store and bought... grub screws... oh well, tomorrow I'm going to try a different hardware store. Also, I'm changing some of the interior bits. The brass core is going to be steel since its cheaper and a tad more durable but you know, mainly cheaper.
 
Today I compiled a few pictures of the emitter claws and made them in SketchUp:
Capture.PNG

After that I imported it to 3d Build so i could convert it to .stl format:
2.PNG

I will probably print these and use them as a template to either A) cut out of aluminum or B) cast out of aluminum. I will most likely be casting them as I have quite a bit of aluminum around for melting but I would have to buy a plate of aluminum. Remember, this is a budget build. So far I've spent about 35 USD on the chassis, the handle, the acrylic bits, the sliding mechanism, and the copper struts along with a few other things.
Capture4.PNG
(This isn't all the 35 USD went into)

I estimate this build to end up being around 50 - 80 USD.
 
Alright, I am finally back from my snowboarding trip so here's an update:

IMG_2470.JPG

The bolt was cut and milled down to the right length and the brass tube was cut to size. In the mail, I got an acrylic blank and a handle.

IMG_2471.JPG
The blank is a bit darker but its okay cos I like it and I'm making it for me.

Things left to do:
Thread the steel chassis
Cut the emitter, slide, and centre pieces out of the acrylic
Cut the copper struts
Mill the copper end pieces, slide stopper, and middle strut holders
Mould and cast the handle out of resin
Figure out how to do the leather grip and do it
Wiring
Cut/Cast the claws and claw holder
Attempt the aluminum slide probably like eighty times and run out of money with half a sonic.

... this is gonna take a while.
 
Yes! I love it too. A bit dark but that's alright, I'm sure it will turn out looking great if I do it right haha
 
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