Custom Tennant Sonic Build

Discussion in 'Replica Props' started by Rassilon, Oct 28, 2011.

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  1. Rassilon

    Rassilon Well-Known Member

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    There has been a lot of controversy on this forum about the Tennant Sonic, so much so I have given it the name the cursed sonic, I don’t wont to dig that all up, this thread is not about past issues OK but about my 10th Doctors sonic build. Over the last several weeks I have been researching the cursed sonic with the help of other forum members that are sonic specialists and from their help and from my own research have got together detailed drawings in 3D Inventor to start a sonic build.
    I have placed an Assembly drawing here for any and all that would like the dimensions to build there own Tennant sonic that I am intending on building please don’t ask me for the manufacturing drawings or step files as you wont get them “why” there is more than enough information on the Assembly drawing to get your self under way, and along with this build thread will be more than enough.

    As you can see I have not totally finished the Assembly drawing still have some design issues to contend with, if you look at the bottom right corner you will see the word REV 1 this means that the drawing is first issue as I have now released it into the general public any further up dates will be REV 2, REV 3, REV4, and so on.

    Now some information on the sonic that I intend on building a prototype of, the sonic will not have any sound but will extend like the real sonic will have a functional blue light, but that’s not all I intend on installing a 2 gig USB memory stick at the end.

    This will make the sonic a very usable peace of equipment and something that you can take with you to the office or use in every day life.
     
    Last edited: Dec 13, 2011
  2. grovergrover

    grovergrover New Member

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    Re: Tennant Sonic Build-Assembly Drawing

    Subscribed.
     
  3. WalkingEye

    WalkingEye New Member

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    Re: Tennant Sonic Build-Assembly Drawing

    Very cool, just this morning I was thinking of making a 10 sonic. Thanks for sharing!
     
  4. Rassilon

    Rassilon Well-Known Member

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    Re: Tennant Sonic Build-Assembly Drawing

    Just a quick update fellow who lovers.
    Was out in the parts store today looking for parts that I know we had for a design that I'm working on, but I could not fined what I was looking for, but while I was looking for that part, I found these blue L.E.D caps, 15.85mm Dia and vintage aircraft warning lights, so they are just rite for my custom Tennant sonic.:thumbsup
     
    Last edited: Nov 3, 2011
  5. Lcars47a

    Lcars47a Active Member

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    Re: Tennant Sonic Build-Assembly Drawing

    Which supplier had those lenses you found?
     
  6. Rassilon

    Rassilon Well-Known Member

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    Re: Tennant Sonic Build-Assembly Drawing

    The L.E.D lenses were in a plastic bag in a box marked blue LED lens covers, thats all that was on the box, the others had no ID at all, but just in a parts box marked vintage aircraft warning dash lights, there is no ID on the lights at all, but I do know that, if you do a search for vintage beehive smooth dash warning lights or vintage car panel lights and vintage military warning panel lights, you may fine some similar.
     
  7. Rassilon

    Rassilon Well-Known Member

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    Re: Tennant Sonic Build-Assembly Drawing

    The transmitter housing that you see that I have made an Inventor 3D image off, and then converted into a step file for the CNC, will be manufactured from stainless steel grade 440 by a CNC lathe and mill.
    To make just one off would cost a small fortune so I will end up making a small amount to justify the cost in doing so. like most of the parts in the Tennant sonic they are cheaper if you do a number rather than just a one off. the workshop is currently manufacturing some D.O.S (Dalek Opening System) parts for my NSD, so I have sent this one of for tooling and machining costs.
     
    Last edited: Dec 13, 2011
  8. Anakin Starkiller

    Anakin Starkiller Master Member RPF PREMIUM MEMBER

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    Re: Tennant Sonic Build-Assembly Drawing

    Your designs look good so far. Why stainless, since the originals were aluminum?

    -best

    Dan
     
  9. Rassilon

    Rassilon Well-Known Member

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    Re: Tennant Sonic Build-Assembly Drawing

    Aluminum certainly would be better for machining and allot cheaper than stainless steel, Aluminum will tarnish over a period of time in the hard to clean areas, that tarnish is called aluminum oxide, due to galvanic corrosion, stainless steel will look the same as it did the day it was first manufactured.

    I know the prop was made out of aluminum. Only the transmitter will be manufactured out of 440 stainless, the rest will be aluminum.
    The real prop was not intended to last, it to has galvanic corrosion in some parts of the transmitter housing, thats the gray and some black marks on the inside of the transmitter housing, thats the part of the transmitter that is hardest to clean, that's were you get the aluminum oxide forming the most, the other parts can be cleaned easily.

    Should it be to cosly to make out of 440 stainless steel then I will manufactur it out of aluminum.
     
    Last edited: Nov 6, 2011
  10. greatwazoo42

    greatwazoo42 Sr Member

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    Re: Tennant Sonic Build-Assembly Drawing

    Wow did you put your data to good use so far. I'm going to enjoy watching this evolve from "what the hell, I'll give it a go" to "lookit what I made!"

    Now if you could link up the light in the front to the "in use" light of the USB stick that would be even cooler. Two things that the original designers wanted in the prop but abandoned because they couldn't do it are a hinge in the ball joint so the head could be rotated 90 degrees (allowing the sonic to be used more like the classic models) and also to have the blue strip up the side glow while in use too. There's been some arguements for and against the glow strip but I'm in the for camp.

    If you want to really drive yourself insaner and try to add those elements you'd have achieved where no one else has so far.
     
  11. Rassilon

    Rassilon Well-Known Member

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    Re: Tennant Sonic Build-Assembly Drawing

    The blue light will be connected to the USB if the USB can drive the L.E.D, will have to look into that as I get closer, as for the pivot 90 deg’s head that would be interesting but cant be chieved, head pivots meens no light, one or the other.

    The blue strip on the side, light it up you say, would you like it to light up at the same time as the blue light on the transmitter.

    Keep in mined, “that” with every inclusion added there must be a price to pay, as in design trade off’s, to have every thing that you are looking for the transmitter would not extend. As well, would have to be bigger to allow for the extra parts to be included.

    Can every one give me your number one thing that you would like to have in the custom Tennant sonic, what must it have, and don’t say sound, have no room as I am installing a USB.
     
    Last edited: Nov 8, 2011
  12. phez

    phez Sr Member

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    Re: Tennant Sonic Build-Assembly Drawing

    Very cool project!!!!!! I love the USB idea.
     
  13. Primrodo

    Primrodo Sr Member

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    Re: Tennant Sonic Build-Assembly Drawing

    Nice find on the Lenses!!
     
  14. Anakin Starkiller

    Anakin Starkiller Master Member RPF PREMIUM MEMBER

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Which version of the sonic are you trying to replicate. Your drawing looks like a hybrid of all of the Tennant and Eccleston props. Is this what you're going for?

    -best

    Dan
     
  15. Rassilon

    Rassilon Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    I was intending on just replicating a Tennant season 3-4 as indicated on the Assembly Drawing, have decided now just to go with a custom Tennant Sonic, I thought it safest by doing a custom than replicate any pacific season or build.
     
  16. mooneye63

    mooneye63 Active Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    In list of wants, mine would be a spring release & push down, as in the CO's Masters Laser Screwdriver. Re the build. I alway thought the ridges on the S1 sonic looked better than s2-4
     
    Last edited: Nov 18, 2011
  17. Felgacarb

    Felgacarb Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Nice work, Rassilon! I'll be watching this one, too-
     
  18. Rassilon

    Rassilon Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Quick releases like the masters I may be able to include that, have received the costing back from the machine shop for the transmitter housing.
    Stainless steel 440 is a no go, as it will take 4 times longer than Aluminium to machine as well as a high tooling cost just for that part alone will cost $65, and that is if I manufactured 25 units.
    Just to build one, well you do not won’t to know, therefore, 440 stainless is out, and will be manufactured from 6061-T6 aircraft grade Aluminium as will all the outer shell of the sonic.
    The estimated total cost to build one custom sonic is going to set me back about $385 for just one sonic, so you see it’s not an affordable build, cheaper to bye one. But were is the fun in that, just as well I have a workshop with CNC mills and lathes to cut the price down will have to do this in my spear time, and by doing this I can cut the price down to about $150.
     
  19. Ull Dar Borealis

    Ull Dar Borealis Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    humm another thing to keep my eye on
     
  20. phez

    phez Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    I am doing mine with hand wheels and it is a big drag :lol:lol:lol. That is an amazing price for the work that goes into one of these. This should be awesome.
     
  21. greatwazoo42

    greatwazoo42 Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    I did mine out of mashed potatoes because, you know...that means something! :lol ;)

    I kid!

    Good luck guys and post pictures!
     
  22. Rassilon

    Rassilon Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Armatures :p
     
  23. greatwazoo42

    greatwazoo42 Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Who you callin' an armature?
     
  24. Rassilon

    Rassilon Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Just having Australian fun with ya all, making one out of mashed patato sound like a real chalange, hey the postman should have been by now wazoo
     
    Last edited: Nov 14, 2011
  25. greatwazoo42

    greatwazoo42 Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Oh he's been today but he didn't have anything good for me. Thankfully he did show up with my wife's birthday present so that's handled at least. :lol
     
  26. Rassilon

    Rassilon Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Well you should have it by now, it's been 2 weeks or so.

    Keep a lookout, in a FedEx bag.
     
  27. greatwazoo42

    greatwazoo42 Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Awesomeness! I'll keep my eyes peeled and stuff.

    Knowing fed-ex it is in a lock down facility in Guam waiting for someone in their customs department to call me and make me explain that it isn't gun or bomb parts...repeatedly.

    Wouldn't be the first time and sometimes I wonder if it's put me on a "extra hard search and question requirement" for when I fly.
     
  28. NakedMoleRat

    NakedMoleRat Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    A spring loaded sonic like the MFX prototype would be awesome!
     
  29. greatwazoo42

    greatwazoo42 Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    ...and a blu-ray laser diode in the front!

    Hey! I can dream, can't I?
     
  30. Rassilon

    Rassilon Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Well it is Christmas, and I am making a list and checking it twice.
     
  31. Rassilon

    Rassilon Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    OK fellow sonic lovers, have managed to get the costing complete on the hard to manufacture parts of my custom Tennant sonic shell completed, and yes I have been checking it twice.

    If you have a drawing of my custom sonic, Now up to Version REV 2
    you then can see what parts cost me to make.

    Made changes to the Transmitter housing p/n DWT-1 to make it cheaper to manufacture.
     
    Last edited: Dec 13, 2011
  32. greatwazoo42

    greatwazoo42 Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    You haven't depicted the slider on your drawings yet. Since you're calling it a custom Tennant I'm guessing you plan on using the thin apeture with the t-shaped slider as opposed to the Eccelston which had a wide opening and a square button. Pictures attached.
     
  33. Rassilon

    Rassilon Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    I have not included the slider in the drawings as I have yet to work out what I’m going to do for the inside parts and how they are going to fit and work together.

    But you are guessing rite, I will be using the T-slider as I think this is a less intrusive design, not sure how I intend on manufacturing this parts.

    This custom sonic is, * you can see is still in the design stage, have some CNC time next week to do a prototype transmitter housing, will get some pics of the CNC in action.

    Before I can work on the internal parts I need to have a shell of the custom sonic, so I can see what USB will work and to see if I can install the slider parts so the transmitter will extend.
     
    Last edited: Dec 13, 2011
  34. phez

    phez Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    I am way over 60hr on my project (it looks like you have much more skill than I do using design software :lol:lol:lol). Every time I think I have it correct something looks wrong :cry.

    Being able to bring a metal piece in at that price range is awesome!!!! I think a lot of people will be able to afford this that would not be able to get one of the other replicas (other than the toys). Great for the holidays :thumbsup
     
  35. Too_Many_Cars

    Too_Many_Cars Active Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Best of luck, this is coming along nicely!

    If you need to go lower on the machining cost I could post the parts on MFG.com and see if I can get some more competitive bids, but I don't see things ever getting cheaper.

    I'm definitely in on a run of these parts when the final design comes together.

    --Brian
     
  36. Rassilon

    Rassilon Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Thanks phez but been working on design software for sometime now.

    Thanks Too-Many-Car for the help with getting the parts made, but if I cannot get them made at an affordable price with all the CNC lathes and mill we have, then I do not think anyone could. However, you just don’t know what’s out there till ya look.

    Anyhow it is company security policy that no 3D design step files of any design work of any kind in any format leave the office via flash drive or net without my approval that’s what all employee’s work under that includes myself, no mater pirate or charity work.

    Why is it so. Well sometime back we gave our design work, to potential customers to review, thinking that we were been of a cooperative manner and showed that we were a company that is easy to work with to win a contract to design and manufacture certain parts.

    Our design work ended up been used by our opposition to manufacture the parts and win the contract our potential customer used us to design the parts and then took it to our opposition to get a better deal.

    Anyhow don’t get me started I could go on about it.:angry

    A quick update on the custom sonic, have finished some of the sonic parts, and by this Friday hope to have a complete custom sonic shell for you all to have a look at, have been working back late into the night to get this one up to speed, not long now.:cool:D

    Oh yeah have been some updates the the Assembly drawing it now is at REF 3
    this is the final updates to this drawing.
     
    Last edited: Dec 13, 2011
  37. greatwazoo42

    greatwazoo42 Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Ah! Something worth looking forward to. Hee!!! :D
     
  38. Rassilon

    Rassilon Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Been working on the designs of the internal workings of the custom sonic, and have ran into some design walls, and by that I mean big things wont fit into small areas.

    The flash drive that I’m looking to install will be a very tight fit, but to do so means that I will loos the ability to have a working light on the transmitter housing.

    As the flash drive will take up the room were the batteries would go to power the transmitter light, and will also not extend as the flash drive is in a fixed position and must remain so as well as the electrical wires that lead from the L.E.D light on the transmitter to the flash drive L.E.D are fixed length.

    Therefore, my options are: until I over come them are-

    Option 1.
    Flash drive Installed, No extension and No working light on the transmitter “but” will work when the flash drive is working., and also would increase the price, so will have to think about this some more.

    Option 2
    No flash drive but have the sonic work as the original and will extended with working light

    This has been going a bit slow due to other sonic projects pushing in as well as design issues to contend with on the internal workings.
    I did mention that I would have a sonic shell to look at, but have been working on the Romana’s Sonic so that has been the delay in getting some pic’s of the custom Tennant Sonic.

    So hang in there, as I will have a shell for you all so. :unsure
     
    Last edited: Dec 13, 2011
  39. greatwazoo42

    greatwazoo42 Sr Member

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  40. Rassilon

    Rassilon Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    The flash drive has to be a particular type it must have the metal part that inserts into the flash drive adaptor.

    As the plastic type are no good as it will brake and make the sonic useless
    And must have a data LED light as well.

    The smaller cheap vertions dont have the above.


    The HP looks like the go, could not find out if it has the data light
     
    Last edited: Dec 1, 2011
  41. greatwazoo42

    greatwazoo42 Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Craptastic. I'll keep thinking.
     
  42. greatwazoo42

    greatwazoo42 Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Bingo!

    http://www.amazon.com/SanDisk-Cruze...7?s=electronics&ie=UTF8&qid=1322790769&sr=1-7

    Micro USB drive and a LED. You could even mod the removable cap on your build to accept the protective case of the USB so you know the fit would be right.

    Trick is to find a supplier that you can get them at a really good discount through. I don't know if the price break that Amazon Seller is giving will hold up for a while or not.
     
  43. Rassilon

    Rassilon Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    yeah that looks the go, will see if i can get them local.
     
    Last edited: Dec 1, 2011
  44. greatwazoo42

    greatwazoo42 Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Glad I could help. I just hope you can get a good price with a bulk order. I don't know if it's a mistake in the listing or not but the price the Amazon seller is pushing them out the door for is kinda weird:

    List Price: $82.99
    Price: $19.99
    You Save: $63.00 (76%)
     
  45. NakedMoleRat

    NakedMoleRat Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Could you machine a body without the slider groove cut out? It would be cool to get one and make it push button, spring loaded instead of a slider!
     
  46. Rassilon

    Rassilon Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Anything is possible NakedmoleRat

    It is charismas
     
  47. greatwazoo42

    greatwazoo42 Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    :lol I read that the same way the one weirdo pronounced "charisma" in the old David Lee Roth video when I read it. I'm still not sure if that's a spelling mistake or on purpose but it is way funny.
     
  48. Rassilon

    Rassilon Well-Known Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    I had to much drink last night,,,,,,,, it shows
     
  49. NakedMoleRat

    NakedMoleRat Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    The more I look at this the more I think it would be cool to try to make a version like the MFX prototype with a spring loaded neck/head assembly. I would just need all the main parts, plus the clear neck and blue tip. I would take a crack at the rest of the insides.
     
  50. Rebelscum

    Rebelscum Sr Member

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    Re: Custom Tennant Sonic Build-Assembly Drawing

    Rassilon1...

    Are you familiar with having aluminum parts alodined? It's a common practice to stop aluminum from surface corrosion, and doesn't change the look of the material. Not that it matters in this instance, but it also remains conductive.

    Companies that anodize aluminum, commonly also can treat aluminum with alodine.

    I use it on my holochess boards after I circular grain them so the nice look never changes. Finger prints wipe right off after treatment.
     
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