Builds By Baz- Full scale Mk II Colonial Viper

Discussion in 'Replica Props' started by sandbagger, Aug 12, 2017.

  1. sandbagger

    sandbagger Sr Member

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    I first had this idea years ago, along with a couple of other projects I may move onto after it. With all the iron man stuff, photography, astronomy and knife making going on, it didn't look like I was ever going to do it.

    A few years ago, tried a paper model from online and just blowing that up and started a life-size cardboard version, but didn't like the shape of it. After sitting in my shed for nearly a year taking up space, I destroyed it.

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    Next I grabbed a Mobeius kit and took Vernier caliper measurements from the physical model and multiplied them by the scale factor of about three. I made a concept model three times the size in cardboard and wood, threw some lights in it and worked out how the modular sections will assemble on site for transport and pull-down.

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    I only built one side of it so the other side can stay open for future visual planning. I mirrored a couple of photos for fun. (above)

    I've been collecting plywood and foam, among other materials for many months. For the last couple of years I've been trying to get shop drawings out of any CAD specialist willing to help, but I understand it's a lot of work for free and it's a big ask to dedicate the time.

    Even using verniers and blowing it up three times, brought inaccuracies I can't accept, so I really needed to get dimensions accurate.

    Now that I have a CAD expert helping me, I finally have accurate shop drawings and have started on the first two and a bit metres of the nose.

    The craft will use a variety of materials to make it, depending on strength/safety and where it is needed. The majority will be plywood frame, some aluminium longerons etc for strength, polystyrene foam fill for sculpting, then skinned with fibreglass.

    The cockpit and undercarriage will be constructed in such a way that it is safe to support and adult's weight and then some.

    The entire ship tops out at 8.4 metres in length.

    I have big plans for the rest of the ship, but I will tell the story as I go, rather than skip to the last chapter.

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    Since my first thoughts of this years ago, I was dismayed to go online searching for blueprints, not finding any, but finding at least two other full scale Vipers out there. One is in full aluminium and a little further along than mine, the other is a plywood, completed and recently unveiled in Manchester. I think they are both 1978 versions, where as mine is the reimagined 2003 version.

    Just goes to show what can happen if you don't act on your dreams right away. Someone else will!
     
    Last edited: Aug 12, 2017
  2. C17ldmstr

    C17ldmstr Active Member

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    IronMan AND a Viper!!?? Amazing.
     
  3. SofaKing01

    SofaKing01 Master Member

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    I am so looking forward to seeing this! :)
     
  4. sandbagger

    sandbagger Sr Member

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    Trying to be sooooo super quiet with the impact driver. It's getting late. Perhaps tomorrow I might get a chance...


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    Last edited by a moderator: Nov 8, 2018
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  5. sandbagger

    sandbagger Sr Member

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    Grinding the ends off the stringer screws.


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    Next stringers plotted out for cutting tomorrow. I have a full day on it tomorrow, so should get a fair bit done. Might even get started on polystyrene bodywork if I'm not interrupted. Not holding my breath though.


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  6. Snow Builder

    Snow Builder Sr Member RPF PREMIUM MEMBER

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    Subbed! Can't wait to for your next post.
     
  7. sandbagger

    sandbagger Sr Member

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    I got quite a lot done today. Finished all the horizontal and vertical stingers in the nose. Then some strategic weight reduction was in order. I broke my 30 year old hole saw set, so it was off to Bunnings for a new and better set.


    Once I plotted out all the vertical stringers I removed them and cut the centres out of all the formers.


    Tomorrow I will attach them permanently and fix some aluminium longerons along the top and sides to lock it all in. Mission accomplished, the frame is now set to be rigid and light.


    To see WIP photos click here


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    Last edited: Aug 17, 2017
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  8. George

    George Sr Member RPF PREMIUM MEMBER

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    Another amazing journey you're about to embark on.
    Thank you for sharing this,SB!
     
  9. sandbagger

    sandbagger Sr Member

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    As always, my pleasure George! I hope I'm up to the task!

    SB
     
  10. Stormy320

    Stormy320 Sr Member RPF PREMIUM MEMBER

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    No he didn't say lifesize. Wait - I think he did [emoji14]
     
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  11. sandbagger

    sandbagger Sr Member

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    Help? Trying to find some reference as to scale, (dimensions) of this panel so I can start making it.

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    Last edited by a moderator: Nov 9, 2018
  12. sandbagger

    sandbagger Sr Member

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    http://www.broadcaststore.com/pdf/model/7123/7123.pdf

    I found this pdf on the consol specs for the entire unit. Looks like it's anywhere between 19 to 22 inches across. If I can establish the actual length of the control panel, I have a scale to work from.
     
    Last edited by a moderator: Nov 9, 2018
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  13. eethan

    eethan Sr Member RPF PREMIUM MEMBER

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    oh, great! I'll be following that project! :thumbsup
     
  14. Apollo

    Apollo Legendary Member RPF PREMIUM MEMBER

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    Awesome let me take her out for a spin when shes done and I will tell you how she flys! :thumbsup
     
  15. sandbagger

    sandbagger Sr Member

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    I got about three hours of frantic cutting, drilling and grinding done this evening.


    All the horizontal and vertical stringers are now secured, along with three longerons along the top for dealing with tension force. As there is compression on the bottom caused by the weight cantilevering over the front skid four metres back from the tip of the nose, there will be a lot of compression on the bottom, particularly closer to the skid. The rear former will need to be reinforced with a solid plate/mounting points. More on that when I get there.


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    Last edited by a moderator: Nov 8, 2018
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  16. sandbagger

    sandbagger Sr Member

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    To start building the body of the fuselage in layers, I found some Sikabond foam construction adhesive at Bunnings. Messy stuff, but does the job well and once you understand how it flows, sticks, spreads and behaves generally, you get the hang of it pretty quick.


    The foam I am using is a combination of soft and hard, but when it’s free recycled packaging and produce boxing, one can’t be too fussy. At the end of the day, once shaped, it will be coated in fibreglass anyway. I’ve built it high and then done some rough shape-cutting with the hot wire cutter. The nose was a little tricky because of all the angles, so the next spaces between formers should be a lot easier.


    I think my hot-wire cutter is running a little cool at nearly two feet long, so i’m going to have to hit the calculator and see what I need do do to turn up the heat.


    Later tonight/tomorrow afternoon I might get a chance to shape it more with a rasp and sandpaper. I have shaped foam before in a small scale and it’s surprising how smooth you can get it. Larger surfaces are obviously easier than intricate hand-models.


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  17. Pro Mod

    Pro Mod Well-Known Member RPF PREMIUM MEMBER

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    A wire brush is another useful tool for styrene shaping.
     
  18. joberg

    joberg Master Member

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    Excellent work there mate:cool One of our member here is building one out of aluminium...Eager to see your project come to life!
     
  19. sandbagger

    sandbagger Sr Member

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    Today I couldn’t do much while babysitting, but while miss two watched on in the back yard sunshine, dad drew templates and threw balls of screwed up paper at her. What fun dad! Giggling her head off!


    A total of about an hour today was all I could manage. I cut some formers for the second half of the fuselage, finishing at the firewall forward of the cockpit.


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    I also spent about five minutes with some 60 grit sandpaper on the nose polystyrene.


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    - - - Updated - - -

    Ok for removing MASSIVE amounts of foam in a hurry and VERY messy.

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    Thank you sir. Yes, I discovered him way back when I was a fair way into my first full sized cardboard Viper that I inevitably scrapped. It's been a long time and the man must have a full life as progress has been pretty slow.
     
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  20. itsgreg

    itsgreg Well-Known Member RPF PREMIUM MEMBER

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    Looking brilliant!
    Using surform tools is a great way to shape your foam, they make really quick work of it. It's what I use for all my patterns, including stuff this sort of size.

    Sent from my SM-N910T using Tapatalk
     
  21. sandbagger

    sandbagger Sr Member

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    I've been researching the instrumentation inside the cockpit, drawing from several sources around the internet. Mostly I'm trying to keep it as accurate as I can, and I really like the cockpit layout in the life size MK II that went up for auction a few years back.

    Many of the instruments are everyday items in modern aviation, along with a few consumer bits of tech for the last 40 years or so.

    Some of the instruments I can source on ebay and the like, others I just have to scratch build. All I needed was a known dimension so that I could scale the rest, using educated guesswork and a Vernier caliper.

    I have an altimeter being sent to me, but these other two instruments I have built from scratch, using the Perspex from a refrigerator crisper drawer, a discarded McDonalds food tray and some printed reference photos hot off the internet.

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  22. sandbagger

    sandbagger Sr Member

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  23. sandbagger

    sandbagger Sr Member

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  24. George

    George Sr Member RPF PREMIUM MEMBER

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    This is so cool :D
     
  25. sandbagger

    sandbagger Sr Member

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    Thanks George. :D

    After a quick paint, (I know it's not the genuine colour.... yet) I used some cardboard to rough out a dashboard cover unit, then transferred it onto 12mm plywood.


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  26. joberg

    joberg Master Member

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    Fun stuff already!! I think your build would be even greater if you'd just add some details on your instruments; nothing crazy, just the needles cut in plastic (not the numbers...that's too crazy) it would certainly add an air of authenticity. Keep up the great work:cool
     
  27. sandbagger

    sandbagger Sr Member

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    Oh them... they're just mock-ups for now. I have real instruments coming. Three on their way already. Hence the radiation warning.

    Baz.
     
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  28. joberg

    joberg Master Member

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    Great:cool!!
     
  29. sandbagger

    sandbagger Sr Member

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    More stealthy work after dark. Everything measured and marked for cutting. Next daylight session- just cut!


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    Got the spar for the second module ready to go.


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  30. joberg

    joberg Master Member

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    Yessssss!!!:)
     
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  31. sandbagger

    sandbagger Sr Member

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  32. joberg

    joberg Master Member

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    Instruments are looking great!
     
  33. sandbagger

    sandbagger Sr Member

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    They are non working or failed calibration, which is why I've been given them.
     
  34. sandbagger

    sandbagger Sr Member

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  35. joberg

    joberg Master Member

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    You mean to say that if your instruments were working, you'd take a spin in that C.Viper:eek...then again, seeing what you did with your IronMan costume, I wouldn't be surprised if you'd try mate:D!
     
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  36. sandbagger

    sandbagger Sr Member

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  37. sandbagger

    sandbagger Sr Member

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    Finished up on the stringers on module 2 at the back. Bolted in a top reinforcing longeron on module 2, some strengthening brackets on module 1. Happy that module 1 is going to support itself on the end of module 2, so it's now onto skinning it with some foam and beginning to sculpt.


    Also, the port side switch for the cockpit arrived in the mail. A rare find and thanks to another Overclockers member for helping me with that.


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  38. Snow Builder

    Snow Builder Sr Member RPF PREMIUM MEMBER

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    Coming along beautifully.
     
  39. joberg

    joberg Master Member

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    Great work so far and the switch is a very nice add-on:)
     
  40. sandbagger

    sandbagger Sr Member

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  41. joberg

    joberg Master Member

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    Good find those old washing machine hoses!
     
  42. AtomicWasp

    AtomicWasp New Member

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    Love the old AT computer switches. :D

    Sent from my Oneplus One using Tapatalk
     
  43. sandbagger

    sandbagger Sr Member

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    A good OCAU citizen just sent me this. Port side cockpit control. Awesome!!!


    You should have seen the markings he put on the box. * myself laughing when I received it! I'll get a photo of it later.


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  44. sandbagger

    sandbagger Sr Member

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    Tonight's work on the front intake.


    I've used ply as a face, pine timber as a frame, plastic bread crate as filter and aluminium angle and flat bar as the grille and louvres. Still got to get a stack of flat bar to finish the louvres.


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  45. joberg

    joberg Master Member

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    You lucky dog! Control is excellent; keep up the great work:cool
     
  46. sandbagger

    sandbagger Sr Member

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    Thanks mate! :D

    Rear louvres to go then install in the nose.


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  47. sandbagger

    sandbagger Sr Member

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    Tonight's work.


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  48. George

    George Sr Member RPF PREMIUM MEMBER

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    Starting to take shape ! Awesome
     
  49. RedheadKevin

    RedheadKevin New Member

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    Looks awesome! One thing to remember though: The Moebius model is based off the CGI model of the Viper. The actual full-sized prop has a lot of subtle differences to the "miniature" used for most of the shots. Good find on the joystick. I thought it was a huge score when I found one at a flea market. 3 bucks!
     
  50. sandbagger

    sandbagger Sr Member

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    Thanks Kev. :)

    Yes it has differences. That's why I chose the original Zoic 3D CAD model, (which is the GGI used in filming), which I have had converted into formers, closing the gaps and lofting the sections accurately.

    The CAD was meant for screen render and was never meant to be fabricated for real. It wasn't intended for close inspection at full size, so the gaps are huge up close. The Moebius kit has too many shortcuts and the actual prop used for filming has a few differences seen no-where else too. I've discovered every single one of them in the last four years of planning.

    Like me, they made do with what they had, as I may have to do periodically along the way but will avoid if at all possible.

    Baz.
     

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