Rassilon Sonic Kit Build & Assembly - Thread

Discussion in 'Replica Props' started by Rassilon, Feb 4, 2012.

  1. Rassilon

    Rassilon Well-Known Member

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    Assembly Part 1

    Hi fellow RPF members and sonic lovers, :) this thread is for the members that have an RCTS that would like to share there builds with other RPF members that also have an RCTS.

    And also that would like more information and or questions on applying crackle mediums and electrics.

    This information is about assembling your RCTS kit, into a working Rassilon custom sonic, for you to give them Daleks hell. :lol
    By now you would have received your RCTS kit in a dry assembled form, this is so you can see that all the parts fit together and that it is all complete.

    The RCTS was design to be broken down into it’s sub components, to achieve this, threads were placed at key areas to help with this feature, along with parts that were not bonded in place to help with the installation of electrical parts.

    The other feature of the sonic is that some parts of the sonic can be replaced should your sonic get damaged due to extreme use or a freak unearthly accident, the sonic is by no means indestructible and the weakest part of the sonic is the acrylic shaft.
    If you have any questions in regards to you RCTS build, this is the place to ask or send me a pm, or if you have suggestions to change the design, so I can make improvements on the next run, should there be one, can also do that here as well.

    The Greatwazoo42 has a video of the RCTS on youtube, and is a very good example of how it go’s back together, but let us now look at doing an assemble build, and how to get the most out of your Rassilon custom sonic.

    A. Braking the sonic into components

    1. Remove the 3mm button head set screw by using a 2mm Allen key.
    by pushing on the slider plate with one hand and at the same time placing the other hand on the crown collar remove the internal brass power slider compartment.

    2. Remove the brass sleeve from inside the sonic grip.

    3. Unscrew the black anodized and silver cap from the sonic grip

    4. Unscrew the transmitter from the threaded ball and remove the brass tube

    5. Remove the blue LED lenses cover

    [​IMG]

    B. Bonding components

    For any bonding of two (2) components I use a two (2) part clear resin glue.
    The first part is bonding the 3.9mm brass tube into the threaded ball section.

    By mixing a small amount of two-part clear resin glue and applying a small amount to the end of the brass tube and inside the hole of the threaded ball.

    Inserting the brass tube all the way into the threaded ball, and making sure to remove any excess amount of glue before it dries from any parts of the thread. No less than 16mm should be protruding from the end. Ref Fig 1.2

    1. Once the two-part resin glue starts to harden and not before, screw on the transmitter housing onto the threaded ball, this is so the brass tube remains straight and keeps it in true alignment, allow to dry.

    And once the glue has set unscrew the transmitter housing from the threaded ball and clean out any resin glue with a 2.5mm drill. Ref Fig 1.3

    2. Now you can polish the brass conduit to your specifications with a brass-polishing agent.

    [​IMG]
    Fig 1.2

    [​IMG]
    Fig 1.3

    C. Crackle finishes using “Derivan” crackle medium

    1. And now we come to one of the hardest parts of the Rassilon Custom Tennant Sonic and that’s the crackle finish on the grip. Aluminum is not an excellent surface to paint so you will need a specific type of paint one that is formulated for such surfaces.

    And that’s the use of etch primer on Aluminum, any other type and it will not work on the Aluminum and just peal off.

    The crackle effect is unique one off the kind, no two-crackle effects are the same, no matter how you do it no matter what you do no two-crackle effect is the same. So your sonic will be unique.

    2. Once you have given the sonic grip a light coating of etch primer and have allowed to dry, you now can use any type of paint within reason, I used gloss black paint, as the base undercoat.

    [​IMG][​IMG]

    3. Next is to lay down an even coat of crackle medium, for this I used an airbrush.
    This is the only way it can be applied; and get a perfect finish you must use an airbrush for this part of the application. Ref Fig 1.5 you can use foam to dab it on, but you will get very small air bubbles and that will show up on the final paint.

    And it must be applied evenly to the grip and “not” allowed to gather into any particular area.

    By placed the grip in the lathe and turned it by hand, at the same time as applying the crackle medium. The first layer is a coating layer and allow to sit for 8 to 10 minutes, at a temp of 25 deg C longer in cold areas. Before applying, a second coat of a much thicker layer, and allowed to sit for about 5 min, “just” leaving it longer will not allow the top coat to crack.

    4. Next is to apply the top coat, this must be a water base paint as it mixes with the crackle medium and you must thin it down so it can be applied with an airbrush. Hold the airbrush about 5” to 6" from the surface of the area been painted, and apply the top coat evenly.

    NOTE
    Do not go over the area that you have painted, this is where you must work on a test peace first, to get your system worked out. Ref Fig 1.6

    [​IMG]
    Fig 1.5
    [​IMG]
    Fig 1.6

    This requires fine tuning as at this point is were you get the types of crackle effect.

    a. To thick and applying it to slow and you will get a cores crackle effect.
    b. Applying it to thin and to fast and you will get a fine crackle effect with the base coat coming though.
    c. This required practice and should be fine-tuned before any attempt is attempted on your sonic parts.

    5. Once you have perfected the art of crackle finishing, give the crackle finish a sealing coat of clear acrylic paint, do not use sand paper on the surface of the crackle finish.

    [​IMG]
    [​IMG]


    The above information was though experimenting with various techniques with various crackle mediums. And also very much with the help of the following members Phez and Anikin Starkiller and Robbertoe

    D. Brass sleeve

    Next is the brass sleeve, I used blue paint and painted just one side of the brass sleeve; you can leave this or polish this part if you so do require.

    [​IMG]

    The brass sleeve has a .5mm deep recess machined into the surface, and this is the part that you would paint, as this is the part seen though the 3mm slot on the grip.

    Do not allow paint to be painted onto the back section of the sleeve as this will upset the tolerances of the slider moving inside of the sleeve. So remove any paint that may get on that part of the sleeve.

    [​IMG]

    Once you have panted that part and removed any paint from the back section of the sleeve, as seen in the photo above, you then can install the sleeve into the grip with the 3mm slot aligning up with the slider grove at the top of the grip.

    E. Electronics

    Now we come to the electrics side of the RCTS kit, and this part is fiddliest part of the build.

    6. Set the pedestal drill up to drill the 2.5 mm hole for the switch extension pin.

    Measure from the front of the brass slider were the acrylic rod fits into and measure back 10mm.
    And make sure it is in the center of the slider, as you do not won’t to drill to one side of the slider plate as this will make the slider useless. ref fig 1.7

    [​IMG]Fig 1.7

    7. Once you have drilled the 2.5 mm hole for the switch extension pin, the next is to drill a recess for the head of the 2.5mm x 12 long socket head cap screw to fit in to.
    Using a 5mm dia drill, back drill 3mm deep Ref Fig 1.8 and Fig 1.9 the 2.5mm x 12 long socket head cap screw needs to fit just bellow the surface, remove any burs from the hole and clean. Ref Fig 1.10

    [​IMG]
    Fig 1.8
    [​IMG]
    Fig 1.9
    [​IMG]
    Fig 1.9


    Ok that's it for this week, next week we will look into installing the tactical switch into the slider housing.
     

    Attached Files:

    Last edited: Aug 16, 2012
  2. Anakin Starkiller

    Anakin Starkiller Master Member RPF PREMIUM MEMBER

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    Looks awesome. Very nice build!
     
  3. DuneMuadDib

    DuneMuadDib Sr Member

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    Just got mine in the mail today, so I'm anxious to see the next part of this.

    Also gotta figure out a decent way to drill the hole in the slider without all that fancy equipment :-\
     
  4. Rassilon

    Rassilon Well-Known Member

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    I did not pre-drill the hole in the sider, as some members indicated that they would like to do something different with the sonic, so I left that part undrilled, so you could do it your way, or you may have come across a better way to install the electrics, however, I should have asked if you needed the part pre drilled or not.

    For anyone that intends on obtaining a RCTS, please indicate if you would like the slider supplied drilled or un-drilled.
     
  5. mobius303

    mobius303 Well-Known Member

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    That is a nice looking kit.
    Great job.
     
  6. DuneMuadDib

    DuneMuadDib Sr Member

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    Meh, serves me right for not thinking about it at the time. I'm sure I'll suss something out.
     
  7. los lobos 26

    los lobos 26 New Member

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    I have a question... What if I can't find the means of drilling my own hole for the electrics on the slider... Is it possible that you would be up to doing an even exchange of just the slider (the non drilled for the drilled)?
     
  8. Rassilon

    Rassilon Well-Known Member

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    Yes for sure, :) If any members that have an un-drilled slider, that feel that they can't do it without some degree of accuracy, and or have changed there minds as to what they were going to do with the RCTS, :confused then most defiantly, send the brass slider to me and I will drill that part for you at no cost what so ever, and send it back, at no cost.

    Each RCTS brass slider is a matched machined fit to your sonics brass sleeve, installing a different slider in your RCTS, would work, however by doing so could give you a tight or overly loose sliding action.

    The same applies to the crackle finish, member backoff, asked if I could installed the electrics and do the painted crackle finish on the RCTS for him, at that time I had just completed a fully working Rassilon sonic.

    I just swapped his RCTS kit sonic for a completed Rassilon sonic, he has
    S/N R-01 and just paid the difference between the kit and the completed Rassilon sonic, the same offer is available to all members that have an RCTS. :) the return postage back to him was fee.
     
  9. greatwazoo42

    greatwazoo42 Sr Member

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    Rassilon, you rock.
     
  10. Rassilon

    Rassilon Well-Known Member

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    Yeah, now that you mention it....... :lol

    No Just doing what I think is the best thing for the members that have an RCTS and for the who fanatics that dont have a big $ buget.

    I do understand that not everyone has the $’s to burn, and or equipment to do the necessary work, so at the end of the day it’s just a little of my time given back to the members that have supported me in this project. :)
     
  11. greatwazoo42

    greatwazoo42 Sr Member

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  12. johnny5676

    johnny5676 Active Member

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    has anyone tried to put the toy electronics into one of these
     
  13. Rassilon

    Rassilon Well-Known Member

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    The RCTS in it’s current form was not designed for the electrics from a toy version, I have not disassembled a toy to have a look at what it has inside that could fit at this point.

    Later on in the year, I will be manufacturing a Rassilon Mk II sonic that will have sound, and will be offered as a completed sonic, there will be no kits available after this version of the RCTS are sold out, this was a one of sonic kit run.
     
  14. los lobos 26

    los lobos 26 New Member

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    I would like to thank Rassilon for an awesome looking david tennant sonic screwdriver. It looks amazing. Once you make the sound version I may be the 1st to ask for one. Now onto the tardis where I have many worlds to see. Thank you again Rassilon!
     
  15. Rassilon

    Rassilon Well-Known Member

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    Thats okay, enjoy and thanks for your support
     
    Last edited: May 2, 2012
  16. Siebigteroth3

    Siebigteroth3 New Member

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    Why not, the Rod of Rassilon, the Sash of Rassilon, the Gauntlet of Rassilon, the Sonic of Rassilon. It only makes sense. Wouldn't it be bigger, more pretentious?
     
  17. Rassilon

    Rassilon Well-Known Member

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    All in good time.
     
  18. Rassilon

    Rassilon Well-Known Member

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  19. greatwazoo42

    greatwazoo42 Sr Member

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    Looking good!
     
  20. Rassilon

    Rassilon Well-Known Member

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    3 minutes may be a bit long, could have shortened it down to 2 minutes.

    I really must get back onto finishing this assembly thread, note to self, lest talk more action.
     
    Last edited: May 20, 2012
  21. Rassilon

    Rassilon Well-Known Member

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    I thought this may be of some interest to the members that have a Rassilon Custom Tennant Sonic, GMB1of1200 has asked if I could do the following modification to a Rassilon Tennant sonic.

    1) Complete Sonic with installed electrics.

    2) Green Dome lens cover.

    3) Handle grip and slider made of Brass.

    4) Have it painted green in the side window instead of the usual blue.


    Once I had worked out some design issues as well as locate the green L.E.D lens cover, I made a start on the Brass grip.

    So far I have completed the brass grip and the power unit slider, and the next step will be to install the tactical switch and tactical switch extension shaft into the brass slider.

    The photo's are showing the Rassilon Brass Tennant sonic in its dry assembly stage, when I have installed the electrics, then I will press the crown collar into the brass grip, as it is an interference fit, as there will be no M2.5 screw holding the crown collar in position.
     
    Last edited: Jun 19, 2013
  22. The0w3n5

    The0w3n5 Member

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    Looking good!
     
  23. greatwazoo42

    greatwazoo42 Sr Member

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    Very cool looking!
     
  24. phez

    phez Sr Member

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    Oh that should look great!
     
  25. GMB1of12000

    GMB1of12000 Active Member

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    This Is going to be sweet!
     
  26. Rassilon

    Rassilon Well-Known Member

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    There has been a design change to the brass grip by GMB1of12000 he has indicated that a medium to light knurling be applied running the length of the energy power window along the side of the grip.

    I could not do this to the other grip as I had already milled in the 3mm (1/8”) slot.

    As well I had to machine in a step up section so the knurling would only be applied in that part of the grip see photo for reference. Oh I know how you guys love action shots or is that just me, :confused anyhow this is a shot of how I set the manual lathe up for machining the brass grip.

    [​IMG]

    So a new brass grip had to be manufactured, this has increased the difficulty factor by the power of 10

    As once I have knurled the section and have parted that off, I then have to drill a 14mm hole for the power slider unit, the hard part is holding the brass grip in the chuck without damaging the knurling.

    [​IMG]

    This will have to now wait till next week, as my new CNC is showing tomorrow, and I have to get that set up for a contract making valve tags for a government ammunition plant. this is were the money comes from to make the sonics. :)

    Well that,s it, till next week when I get more time.

    Oh yeah GMB1of12000 has given his design a name: "Rassilon Enhanced Sonic”
     
    Last edited: Jun 6, 2012
  27. sonicprops

    sonicprops Active Member

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    i really like the brass handle and prefer it to the crackle paint but like the crackle as well.
     
    Last edited: Jun 8, 2012
  28. Rassilon

    Rassilon Well-Known Member

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    Could do maybe a one of box set:

    Rassilon Custom Tennant very limited edition Sonic Box Set No1

    In the limited edition Sonic Box Set will be:

    Rassilon Brass Custom Sonic
    Rassilon Custom Tennant Sonic with crackle finish
    Rassilon Flash drive Sonic with crackle finish with 8Gb flash drive installed

    Just a thought.
     
  29. sonicprops

    sonicprops Active Member

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    sounds amazing. you should defiantly do a river song sonic screwdriver.
     
  30. Rassilon

    Rassilon Well-Known Member

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    It’s just been one of them there weekends, and it all started to go wrong about lunch lime, first, I was operating the CNC and during the set up stage I did not check the cutter feed rates and when I hit the GO button, I drove the cutter into the deck, yeb that’s going to cost me big 2 cents and some.

    And from there on it just got worse, every thing I touched I broke, next was the locking knob on the cross slide of the lathe, yep that’s right, I broke that to, :angry and to top it off I was milling the last 1/8” slot in the brass grip and it came loos, yep the cutter started to eat the brass grip. :angry :angry :cry

    So here are some action shots of the grip before the mill cutter started to eat it for lunch.

    [​IMG]

    [​IMG]

    So I had to start a new brass grip from scratch, So now I was real :angry :angry and then I started to :cry but I held it together, and got the new brass grip finished with a dry assembly fit with the blue L.E.D lens cap in place for looks, till the other green lens caps turns up, I think it will be this week.

    [​IMG]

    [​IMG]

    Well that's it...........Im going to have some Aussie :cheers and hope I dont have a day like that again.
     
    Last edited: Jun 11, 2012
  31. greatwazoo42

    greatwazoo42 Sr Member

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    Holy cow! That's just...wow. That is a real kick up a notch. Bravo, Keith! That looks killer!
     
  32. phez

    phez Sr Member

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    Yup, I hate it when that happens. Ever notice that can never happen before you have 4-8 hours in on a part that is a nightmare to machine :lol. I am so paranoid of that happening now that I check to make sure that nothing is lose between every couple passes.

    This one is my all time favorite. You can see where the bit came lose, dropped into the window and just tore up the top of the head :lol

    [​IMG]
     
    Last edited: Jun 11, 2012
  33. GMB1of12000

    GMB1of12000 Active Member

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    Keith,

    So sorry about the difficulty you had.
    WWWWWWOOOOWWWW!!, you did an amazing! Job.
     
  34. Anakin Starkiller

    Anakin Starkiller Master Member RPF PREMIUM MEMBER

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    That looks gorgeous. Great Job!!!
     
  35. Tom Starkiller

    Tom Starkiller Well-Known Member

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    The pictures aren't showing for me. But the ones on the previous page look great. xD
     
  36. Rassilon

    Rassilon Well-Known Member

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    Thanks guys, the green lens caps have showed up just now, so I think I will have a good chance to get the Rassilon Enhanced Sonic completed this week.

    Hey phez 4-8 hr’s of work, yeah I would be very :angry it takes about 1.5 hr’s to make a Rassilon custom Sonic grip from scratch, so I lost about 2 hr’s with set and materials, but that’s how things can happen with machining.
     
  37. GMB1of12000

    GMB1of12000 Active Member

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    Hi Rassilon

    Do you know when paymint might be due?

    Also for those who want both the brass grip and crackle grip
    with blue lense, what would be the extra cost?
    Thanks
     
    Last edited: Jun 15, 2012
  38. Rassilon

    Rassilon Well-Known Member

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    Hi Rassilon Custom sonic lovers.

    Have installed the electrical components and also the green L.E.D lens cap, the Rassilon Enhanced sonic is now 95% complete.

    I only have to find some green paint for the power window on the grip, and it is complete, the sonic feels quite heavy due to the brass grip giving it that extra mass.

    [​IMG]
    [​IMG]

    GMB1of12000 I will have to work that out, as your sonic is very much unique to the others standard Sonics as your sonic has no slider brass sleeve for the power slider to slide in, the sleeve and the brass grip in yours are one component and not two individual components found it the standard Aluminum grip type Sonic.
     
  39. GMB1of12000

    GMB1of12000 Active Member

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    Now that looks Fantastic!!
    I love that you also used green wires in the acrylic section.

    Looking forward to it ;)
     
    Last edited: Jun 17, 2012
  40. Tom Starkiller

    Tom Starkiller Well-Known Member

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    Still not showing the pictures. :/

    Does sound good, though. xD
     
  41. GMB1of12000

    GMB1of12000 Active Member

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    Tom Starkiller

    You can see the pictures in Rassilon's Picture Album gallery in his profile listed under
    " Rassilon custom work for members"
     
  42. Tom Starkiller

    Tom Starkiller Well-Known Member

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    Thanks for the tip, however I don't seem to be able to select an album. :confused
     
  43. phez

    phez Sr Member

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    Great job Rassilon. That looks amazing!!!
     
  44. Rassilon

    Rassilon Well-Known Member

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    Thanks Guys, found another photo of the Rassilon Enhanced Sonic. Yeah I thought I took 4 photo’s of that Sonic. :)

    [​IMG]

    Tom Starkiller, dont know why the photo's are not showing up, that happens to me as well on some threads. :cry
     
  45. greatwazoo42

    greatwazoo42 Sr Member

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    Bravo! That looks fantastic!
     
  46. Organic Mechanic

    Organic Mechanic Sr Member

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    That looks great Keith!

    Also reminds me, I need to get to work finishing MY Rasilon's Sonic. Perhaps I should do THAT while waiting for my casting supplies. :cool :thumbsup
     
  47. Tom Starkiller

    Tom Starkiller Well-Known Member

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    Must be that damned chameleon circuit.

    EDIT: Even switching to Chrome from Firefox hasn't helped. Odd, because I can see the earlier pictures in both.
     
    Last edited: Jun 18, 2012
  48. Anakin Starkiller

    Anakin Starkiller Master Member RPF PREMIUM MEMBER

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    Looks great. What size Cabochon did you use for the lens?
     
  49. Rassilon

    Rassilon Well-Known Member

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    That is a very flashy word Anakin, “cabochon” you made me go and look that up…… :$...... I have never heard that been called that before. However, that is not what it is; it is just a dashboard warning light lens cap.
     
  50. Anakin Starkiller

    Anakin Starkiller Master Member RPF PREMIUM MEMBER

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    Oooh. Cool! It looks great. I really think it fits the prop perfectly. LOL. I have to look up the word every time I try to use it too. I only know it because I use glass cabochons on my own build and I thought that the green lens looked similar. I ordered a couple 16mm Cabochons today to see what they would look like in your sonic. I'll post pics once I test them out.


    BTW, I found this cool pic of the concept art for the River sonic, and it had one of Tennant's sonics next to it. And I think that your sonic looks nearly bang on to the Tennant sonic in this pic, except for the slider of course.

    [​IMG]

    -best

    Dan
     
    Last edited: Jun 18, 2012

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