Dr. Who: Key to Time (in Lucite) - Factory Production Photos

[Dalex]

Hey guys,

This post is long overdue.

Last year I co-ordinated a project to build a replica of the Key to Time from Doctor Who:

The factory that built these replicas was kind enough to provide some behind-the-scenes photos of the production process, showing the work that was involved in hand-cutting these pieces out of Lucite.

I thought people here would appreciate seeing these photos, so I got permission from the factory to post them.....

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The Lucite used to make the Key to Time begins as a slurry, which is baked in an oven until it hardens into a solid block of Lucite. It is from these blocks of Lucite that the individual segments of the Key to Time are cut:

The Lucite can be tinted, so some people in our group had their Key to Time done with a pinkish-purplish hue:

Everything is precisely measured and marked in preparation for the cutting process. The blocks are mounted on a custom rig (itself made of Lucite) and a band saw is used to cut individual segments from the blocks:

 

[Dalex]

Here are some of the initially cut pieces. They appear to be translucent but are in fact crystal clear, it is only the surface that has this appearance because it hasn't been polished yet.

Here's a series of blocks in the initial stages of being cut:

The factory had cardboard replicas of the Key to Time segments that I made, which they used as a reference during production:

More cut pieces, including a full cube:

Definitely becoming recognizable as the Key to Time:

Several cubes ready for the next stage:

 

[Dalex]

The next stage is making the tracer holes. These are half-inch holes that are drilled through the center of the cube on each axis. In preparation for this the cubes are tightly bound together:

The cubes are carefully aligned on a drill press:

And then the drilling can begin:

The next stage is the sanding and buffing of the individual segments. This is one of the sanders that are used. (Note some of the photos below are of segments being polished before the drilling process.)

One of the particularly time consuming aspects is polishing the tracer holes. Much of this has to be done by hand.

To polish the 5th segment's tracer hole the factory used sandpaper wrapped around a drill bit. Also in the photo is a segment that has been partially buffed.

A shot of one of the tinted cubes in the process of being buffed:

Some of the nearly finished cubes, awaiting final touch-ups before they are considered truly done:

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A whole bunch of finished Key to Time cubes, ready to go!

A final shot of the various Key to Time cubes and segments:

And that's pretty much it! If you have any questions, feel free to ask.

Cheers,

 

[TimeyWhimyStuff]

Absolutely beautiful.

 

[Risu]

This is still the single greatest prop I've ever seen made. Absolutely beautiful result.

 

[Jintosh]

I saw key to time episodes on tv when they aired originally. Haven't seen them since. Seeing this brings back nostalgia. I may have to seek out those original episodes.

 

[Einstein]

Awesome project.

Thanks for sharing!
Ed