Custom Tennant Sonic Build

[Rassilon]

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.

 

[grovergrover]

Re: Tennant Sonic Build-Assembly Drawing

Subscribed.

 

[WalkingEye]

Re: Tennant Sonic Build-Assembly Drawing

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

 

[Rassilon]

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

 

[Lcars47a]

Re: Tennant Sonic Build-Assembly Drawing

Which supplier had those lenses you found?

 

[Rassilon]

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.

 

[Rassilon]

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.

 

[Anakin Starkiller]

Re: Tennant Sonic Build-Assembly Drawing

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

-best

Dan

 

[Rassilon]

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.

 

[greatwazoo42]

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.

 

[Rassilon]

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.

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.

 

[phez]

Re: Tennant Sonic Build-Assembly Drawing

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

 

[Primrodo]

Re: Tennant Sonic Build-Assembly Drawing

Nice find on the Lenses!!

 

[Anakin Starkiller]

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

 

[Rassilon]

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.

 

[mooneye63]

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

 

[Felgacarb]

Re: Custom Tennant Sonic Build-Assembly Drawing

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

 

[Rassilon]

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.

 

[Ull Dar Borealis]

Re: Custom Tennant Sonic Build-Assembly Drawing

humm another thing to keep my eye on

 

[phez]

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.

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