Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with Risu)

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Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

I got that aluminum bar cut out with my Dremel Trio, and now I've cleaned it up and wet sanded it down to 1500 grit. I'll polish it after it's cut apart and bent. I have an extra difficulty level because I realized that in order to keep the toy's spring loaded system for the claws, I can't have the 90 degree angle bars that stick out into the center, I have to keep these ones pressed against the inside of the silver arms. So that means two 45 degree angle bends per bar and they need to be spaced perfectly. If I mess up once, I have to cut another bar. This is going to give me so many headaches. It makes me wish I had a work bench with a vise.
 
Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

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Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

This thing is killing me. After multiple test fittings, I still can't hollow out enough of the inner black casing from the front end to allow the green shaft to slide through unrestricted. On top of that, the process of cutting away the innards has completely removed the screw holes that hold the prop together. One flick and the whole front half flies off. (assuming I can get it thin enough for the green tube. Right now that's the only thing holding it together.) All in all, this has been the most frustrating part of the build. Even more than the spring loaded claws, although I'm sure I'll have more thoughts on those when it comes to lining up the tiny holes for the pins.
 
Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

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Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

If that's the case, you must have slightly moved where the claws are mounted, because they fit tight on mine when I hold them in place.
 
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Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

If you build up the inside edge of the very bottom (forked) end of the claw with a piece of 1 mm styrene, the problem will be solved. The remote copper body has a notch that the claws fit into with a tiny bit of give, that will fill the gap.
 
Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

Pictures of my progress:

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I hadn't realized it before, but the stitching on the "leather" bit doesn't line up properly with the silver arms. Instead it line up with a copper arm. Functionally it doesn't make a difference, but it's technically inaccurate. I need to train myself not to ever look at pictures of the filming prop again.
 
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Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

Not sure if you want to take your screwdriver apart to fix the issue with the claws being hollow, but here is a fairly easy solution. Alumiweld. You can get it at Harbor Freight. It is a low melting point aluminum alloy rod that can be used to fill or weld(braze) aluminum. Just hit the piece with a torch and work the alumiweld into the hollow areas, then grind and sand smooth. I have used it on a lot of aluminum projects where holes need to be filled etc.. The only thing is that I'm not sure what the claws are made from, if they are white metal or tin they may melt before the alumaweld.. if they are aluminum you should be good to go. All you need is a propane torch.
 
Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

" One flick and the whole front half flies off. "...

Gives a whole new meaning to the phrase 'you'll take some ones eye out with that.' As your victim is pinned to the wall by the 4 prongs of half a sonic screwdriver. :lol
 
Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

Yea, I still haven't figured out the solution for that yet. The tolerances are too tight, the mechanics of it don't work. I might just have to put the toy back together and bag the rest of the parts indefinitely.
 
Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

When you remove the "leather" piece, there will be a raised channel on the black housing. This raised channel is what controls the alignment of said leather piece. Just shave it down and you will be able to rotate the thing any which way you want.
 
Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

And then just glue it in place? That would work, yea. I was referring to the tolerances of the black plastic pieces and the green shaft, though. I can't make it work. I know you did it a different way with separated electronics, but do you have any idea how I might be able to hold those pieces together? I thought about cutting the screws down so that they barely extend through the outside piece, but then the sonic would be held together by a pin or two that only about 1 mm away from working it's way free. I'd also have to send a good 1mm of wall thickness off of the green tube, which would make it pretty darn ugly when the sonic is extended.
 
Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

I think sanding then polishing the green shaft could work. As far as the shaft sliding, the toy shaft and my resin cast shaft are the same OD. You could probably try sanding the toy shaft down then polishing it with progressively finer grits of sand paper. As far as securing the two halves together, I just used JB weld to secure the black connector piece to the bottom of the copper cage. The twist lock mechanism holds and the two shaved down screws hold the two halves together just fine even with a flicking motion.
 
Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

Oh, so you did the shaved down screws and they hold?
 
Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

Yep. Shaved them down an they hold pretty well.
 
Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

That kind of blows my mind. Any chance you can post a pic of how long they ended up being and of the twist lock mechanism/area?
 
Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

I kept the screw at 4mm long which is just a tiny smidge over what it needs to be, that way I can adjust the tightness of the sliding action.
 
Re: Turning a Sonic Screwdriver remote control into a Sonic replica (Round Two with R

any chance of showing pictures of the screw area. Im not sure i know what you are talking about.
 
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