Need help with my Sonic Screwdriver Remote conversion!

[The Artist]

Hello everyone!

I don't know if this is the right place to post this, yet I really really hope it is...

Here is my problem: I am currently working on an 11th-12th Doctor Sonic Screwdriver Universal Remote Control conversion into a prop replica, and I start facing some problems.
I have already dremeled the top parts to make the top of the sonic extendable, so no problem with that. (see pictures below)



It gets harder now as I am not sure how to manage the internal parts.
I would like to use the Character Options toy components but I'm not sure how to work it out.

Can someone help me get it to function easily, with the button correctly placed on the handle, without having to 3D-print anything or buy any expensive parts?

Thank you in advance everyone!

 

[Captain]

Pm Kursasawa! He's always happy to help people. Super cool guy.

 

[The Artist]

I think I... Somehow... Did it already...
No answer yet from him, but it didn't stop me from going forward on my conversion.

It is now almost done, totally safely flickable and everything is in its place.
All I need to finish now is the polishing, the springs for the claws and find out a proper way to manage the internal wirings. Any idea for this?

 

[kursosawa]

Odd, I never got an email/PM. As for the springs, you can use either linear extension springs like the prop, but they would need to be mounted to a central post, or use torsion springs (like I use for mine) and have them press against the body. As for the wiring, it all depends on how you set up your electronics.

 

[The Artist]

Really? I remember sending you an email...
Nevermind, thanks for answering

I kept the green core from the toy as I could not work anything else out. That means the electronics are sliding, too, and I'll have to keep it like that even if it is going to break eventually.
Yet I was thinking of using copper wires for the flexibility, and (tell me if it is insane) maybe get a spring pulling them down the bottom of the sonic so they won't end up stuck between the structure and the green core and break.

For the springs, I want to know how important it is to get a claw holder instead of keeping the buckles from the remote... I had to do this for the moment and it makes the claws really wobbly.
Has someone here already tried to keep the buckles from the remote? Can you tell me if they stop wiggling when the got spring-loaded?

Thanks!

 

[kursosawa]

I assume you are talking about the switch wires right? One way to handle those is run the switch wires from the bottom of the toy core to the momentary switch that will be installed in the handle. There is little to no risk of them catching and snapping.

As far as the claws are concerned, yes a claw holder set up is necessary as the buckles on the remote are a made from very soft metal and will snap. I hope that helps.

 

[The Artist]

Oh, I'm glad to hear this! I was worrying about how often I would have had to replace the wires...

I will then order it this week, thanks!

 

[The Artist]

Hello again

One of the buckles just broke as I was trying to insert my homemand springs (these fit perfectly and give a nice strength by the way)
So while checking Shapeways, I looked closer at the dimensions they promise here: http://www.shapeways.com/model/330704/11prong-holder.html?materialId=23
I compaired with the corpse of my sonic and the part from Shapeways seems shorter than the buckles from the original body... Is someone able to tell me if the prong holder is perfect fit on the remote?

(Please I'm desperate)

 

[The Artist]

The guy who sells the parts told me the prong holder is not designed for the remote...

Wht do you guys use for your conversions?