Star Trek TOS Door Chime minor modification

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Hey, guys... I just wanted to share with you a very minor mod I did to the Think Geek Star Trek TOS Door Chime/Intercom Panel.

I got it from Think Geek about a week ago, and I thought it was pretty good. But of course, after about 5 minutes, it was already taken apart. The one thing that bothered me was the gold plastic grille where the speaker is. I thought I could cut it out and use some of the TOS-style grille cloth to replace it. So I did just that. Got out the Dremel and cut out the window for the grille. Got a piece of Fender grille cloth, and lightly painted it gold, as to retain the color of the original plastic piece that was there. I took a thin sheet of plexi and drilled holes for the sound to escape, and glued that to the back of the grille cloth. (It wasn't rigid enough on its own; it needed some sort of backing.

The other thing I wasn't too crazy about was the sky blue housing around the speaker. While the shiny red main housing looks pretty good, that pale blue just looked too plastic to me. So I used a rattle can of Duplicolor blue metallic to cover that up. Again, I wanted to maintain something of the original color scheme, so I stuck with blue, but just not as light.

Got everything together, and there you have it. I've included a few pics. Thank you for looking! :thumbsup

First is the original version: (Image © Think Geek)
ST_DoorChime_original.jpg



Here's a full shot:
ST_DoorChime_full.jpg



And a couple of close-ups to see the gold grille and paint. The blue isn't quite that saturated in reality; it's a bit more subdued. The photos aren't completely accurate insofar as that.
ST_DoorChime_closeup1.jpg


ST_DoorChime_closeup2.jpg
 

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Thanks, guys!

22 Stars, if you're thinking about doing it, this may help-- it's the template I made for the thin sheet of plexi that I put behind the grille cloth. I printed this out, laid it in the inside of the speaker housing (the blue plastic piece) and did a little more trimming to ensure a proper fit. (As it says on the diagram, the cutouts on the four corners are approximate locations.) I then just traced the paper template onto the plexi and cut. It's not perfect, but it'll get you going in the right direction.

StarTrek_TOS_intercom2.jpg


Incidentally, when you cut out the original grille, you're going to lose 1 (or is it 2?) of the screw holes that keep the larger of the two circuit boards in place. But it still seemed to stay just fine, despite the fewer connection points.

I also took a thin piece of plexi and made a ring to go around the speaker itself, to act as a bit of a resonance chamber. Not that the speaker needs it for volume-- it's pretty damn loud to begin with. But I just wanted to make sure I rounded out the sound a bit.
 

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