Doctor Who: New Series Dalek 2005 Build
- Thread starter Maximushaydos
- Start date
Maximushaydos
Active Member
I can ask mate no worries at all, however I have a feeling the shipping from here to there would cost a hell of a lot.
Maximushaydos
Active Member
Good afternoon all! Big push on Dalek Sec this weekend with 8 hours of non-stop (and I do mean non-stop) fiberglassing. We completed the Dome, Cowl, Shoulders and Fender in one massive day!
First we did the Dome and Cowl in our silicone mould. We applied two layers of Gelcoat followed by 2 layers of fiberglass. This is the first layer of gelcoat in the mould.
Next we moved to the reverse fender buck and once again did two layers of gelcoat and then ended up doing 4 layers of fiberglass for strength.
After that we moved on to the shoulders and yep you guessed it, two layers of gelcoat and 3 layers of fiberglass!
The shoulder buck is in three parts so we did all three segment's and then bolted them together, putting three layers of fiberglass over the joins. Once the three layers were together we attached the bottom of the buck and did three layers around the bottom.
Here are the parts in between fiberglassing, this was honestly a massive but awesome day.
So everything was demould that afternoon and everything popped out fantastically. No issues what so ever and will require very little clean up!
So this is where we sit at the moment, there are three MDF neck rings under the dome and cowl in the photo, I need to build the neck cage next and then start all the clean up work and fine details.
Really happy with how it is turning out I have to admit!
Maximus
First we did the Dome and Cowl in our silicone mould. We applied two layers of Gelcoat followed by 2 layers of fiberglass. This is the first layer of gelcoat in the mould.
Next we moved to the reverse fender buck and once again did two layers of gelcoat and then ended up doing 4 layers of fiberglass for strength.
After that we moved on to the shoulders and yep you guessed it, two layers of gelcoat and 3 layers of fiberglass!
The shoulder buck is in three parts so we did all three segment's and then bolted them together, putting three layers of fiberglass over the joins. Once the three layers were together we attached the bottom of the buck and did three layers around the bottom.
Here are the parts in between fiberglassing, this was honestly a massive but awesome day.
So everything was demould that afternoon and everything popped out fantastically. No issues what so ever and will require very little clean up!
So this is where we sit at the moment, there are three MDF neck rings under the dome and cowl in the photo, I need to build the neck cage next and then start all the clean up work and fine details.
Really happy with how it is turning out I have to admit!
Maximus
DoctorEight
Active Member
Wow, really shaping up!
Maximushaydos
Active Member
Thanks DoctorEight, slowly getting there. It was a big day of fiberglassing and since it was my first ever time doing it I was pretty happy. There are some tips I have picked up for next time but I am happy with the result.
Do you have any pictures of making the mold for the the shoulder part, or the original you molded from.
I will be doing a new mold for my build soon.
I will be doing a new mold for my build soon.
Maximushaydos
Active Member
The shoulders are made by good friend of mine, same person that laser cut the base for me. I will have a look around and see if I can find the pictures of her original buck.
BlobVanDam
Sr Member
Now it's starting to resemble a Dalek! Looking good so far. :cool
Maximushaydos
Active Member
I was thinking that with this one I will either make it a static display with casters for pushing it around, as it will be displayed in my house next to the TARDIS and my other Dalek. But I am planning on making another one after this which will use a modified electric wheelchair. A friend of mine has one inside her Dalek and it is awesome. Gets up to some pretty good speeds as well.
Here is something you Dalek builders might want to consider--a jamming gripper:
Universal robotic gripper based on the jamming of granular material | Cornell Creative Machines Lab
This would replace the Dalek plunger with something that actually picks up objects.
What may have inspired the Daleks--Sputnik III, also called "Object D"
Sputnik 3 - Scientific Laboratory
Universal robotic gripper based on the jamming of granular material | Cornell Creative Machines Lab
This would replace the Dalek plunger with something that actually picks up objects.
What may have inspired the Daleks--Sputnik III, also called "Object D"
Sputnik 3 - Scientific Laboratory
Maximushaydos
Active Member
Thanks for the links Publiusr, very interesting indeed! Might look at the gripper for another one I am doing after this one.
Did you manage to find details the pictures of the original shoulders?
Will look great next to a tardis when done.
Will look great next to a tardis when done.
Maximushaydos
Active Member
Small update on the build. I have given the fender it's first sand so that I can see where needs filling and more sanding. I just used 120 wet and dry and did a dry sand to start with to knock of any dags and to highlight any lows in the fiberglass.
I will be getting into the build next week as the wife is going to America on work for 3 weeks, which means I can dedicate more time to the build! Wooohoooo! No I mean I will miss her..... DALEK BUILDS, Wooohoooo! lol.
I will be getting into the build next week as the wife is going to America on work for 3 weeks, which means I can dedicate more time to the build! Wooohoooo! No I mean I will miss her..... DALEK BUILDS, Wooohoooo! lol.
Maximushaydos
Active Member
They do look great next to the TARDIS, this is my Bronze NSD next to my TARDIS here at home. (and the bum of one of my German Shepherds in the background lol)
Maximushaydos
Active Member
Little more progress on Sec, I have got the neck rings all together and neck ring struts in place with blocks completed. I need the very top ring done to hold the dome in place (as you can see it hangs over the top ring).
Hoping to get a lot more done over the next few days.
Here is the neck completed without the blocks, it will hide a lot of my mistakes!
Getting there now, A little more cleaning and some more building and I will be ready for more work...
Hoping to get a lot more done over the next few days.
Here is the neck completed without the blocks, it will hide a lot of my mistakes!
Getting there now, A little more cleaning and some more building and I will be ready for more work...
DoctorEight
Active Member
Coming along nicely. I think I have enough material for my skirt, need to get the panels measured out and get started.
Maximushaydos
Active Member
So after a long build hiatus I thought I would get stuck back into the build! Don't you hate when real life stuff gets in the way of building things! Damn real life! But anyway, I have now attached the fender to the skirt with 6 bolts, sanded the and filled the fender to 1200 grit wet and dry (so smooth!) and put together the 'oil seals' for the hemi's. I have also attached the hemi 'oil seals' to the skirt where I will now give the sides of the surround a quick brush over with watered down PVA glue before I prime the skirt and fender.
I have also bolted the shoulders to the skirt now and have started to clean up the slats that run around the shoulders. They have been built out of MDF so there is a little bit of filling and sanding that needs to be done.
I am back building with a view to having it completed in a few weeks so I can move on to the next Dalek that we are making, that is going to be a doozy of a build!
Maximus
I have also bolted the shoulders to the skirt now and have started to clean up the slats that run around the shoulders. They have been built out of MDF so there is a little bit of filling and sanding that needs to be done.
I am back building with a view to having it completed in a few weeks so I can move on to the next Dalek that we are making, that is going to be a doozy of a build!
Maximus
