Rebuilding a Classic - The Star Trek Communicator!

Corellianexports

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During my last move, I discovered this beauty packed up inside a spare Playmates communicator box. I had thought it had been lost during another move and wrote it off long ago. Unfortunately, over the last 15 years (I bought it at a ST convention in Portland back in 1991 for around $60) the epoxy that was used to hold it together disintegrated and the entire prop fell apart! Even worse, one of the machined, aluminum washers was missing.

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Today is my day off from every thing and since we had a rain storm come in, I decided it was a good day to fix this prop up. I took every thing apart and lightly sanded off the old, yellowed epoxy. I used a little nail polish remover to clean off the residue. I was surprised to find that the metal section was actually cast metal, so it's very pliable. The "clam shell" pieces are actually vacuum formed PVC with the 60's texture. No doubt the original master from the TV show was made the same way.

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After cleaning every thing up, I glued one of the shells to the metal section with some contact cement and let it set.
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In the mean time, I machined a replacement washer for one of the rinestones. Due to the small size, it's a tricky part to machine. It actually took two attempts before I could make one that looked good enough.

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With the part done, I continued the assembly and viola!

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She's back together and better than before! :D
 
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Nice repair, and congrats on finding it! That looks like an early HMS, very similar to the ones sold by Rodd.com today. If so it's probably ABS plastic, the originals were made from Kydex.
 
Great rebuild. I came across a comm in a comic book shop similar to that a few years ago that I let sit in the display case as they were asking $80.00 for it. Not that it was not worth that price but the build on it was bad. Epoxy city...To this day I kick myself for not rescuing it. It was fixable :cry
 
Nice repair, and congrats on finding it! That looks like an early HMS, very similar to the ones sold by Rodd.com today. If so it's probably ABS plastic, the originals were made from Kydex.

I was going to say it reminds me of my Steve Horch Comm that I bought back in the early 1990's, which I still have.

Nice job on the repair.
 
I have one, I don't know when it was made, but it seems to have the same lid as the Roddenberry.com communicators with more holes than the one Corellianexports has shown. Other than that, it's identical.

Anyone know when Horch started using the lid pattern with more holes drilled out?

Here's mine:

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^I really like the side profile, a little thick, but still slimmer than many of the other available communicators of the era, with the only possible exception of the Chad Roadhouses.

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Don't know if it was or not, but it was pretty well built. I did take the front shell off and evened out the lid wheel slots that were cut into the shells and centered the shell to the mid plate better.

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