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  1. Member Since
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    Apr 15, 2012, 1:50 PM - Re: Long Range Shuttle - Surak #26

    Eeeep! Ummm....wow. That wasn't the update we were A) expecting, and B) hoping for.

    Stay sane. Nice thing is - acrylic has a looong shelf life. So it will be there when you are ready/able to get back to it.

    Regards,

    Gene
  2. Member Since
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    Apr 16, 2012, 4:09 PM - Re: Long Range Shuttle - Surak #27

    Thanks, guys. I appreciate the support. I'm maintaining my optimism about my future and life in general....just taking things now a day at a time. When I do get back to building again it's going to be full steam ahead. I'm looking forward to that.
  3. Member Since
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    Apr 26, 2012, 8:04 PM - Re: Long Range Shuttle - Surak #28

    Getting caught up with posting my previous progress.

    This is the line bender I'm using at the TechShop. It makes bending the acrylic a piece of cake.


    And the adjustable fence for bending to the correct angle.


    The main challenge with bending the 1/4" acrylic is that it tends to want to bend to a particular radius every time and not the right radius. The radius it wants to bend to is too small. On some 1/8" acrylic test pieces I realized that the outside radius of those bends is just about right for the inside radius on the 1/4" acrylic. So I made a form to bend over to force the 1/4" acrylic into the right shape. These photos show that process.



    Last edited by dbhs; Apr 27, 2012 at 11:05 AM.
  4. Member Since
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    Apr 27, 2012, 11:06 AM - Re: Long Range Shuttle - Surak #29

    This is a mockup with the first test piece of the 1/4" acrylic just to get a sense of the size of it. The 2 nacelles are test pieces and both starboard nacelles.

    It's really cool seeing it take shape finally. I love the size of it. Going to be a lot of fun to paint and weather at this scale.







  5. feek61's Avatar
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    Apr 27, 2012, 12:01 PM - Re: Long Range Shuttle - Surak #30

    Glad to see you are back and great update!!!
  6. IEDBOUNTYHUNTER is offline IEDBOUNTYHUNTER
    Apr 27, 2012, 12:05 PM - Re: Long Range Shuttle - Surak #31

    Looking cool.
  7. Member Since
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    Apr 27, 2012, 12:07 PM - Re: Long Range Shuttle - Surak #32

    Very nice, cant wait to see it finished
  8. Member Since
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    Mar 12, 2015, 4:15 PM - Re: Long Range Shuttle - Surak #33

    I haven't posted an update here in quite some time. Here's a brief summary.

    Shuttle internal armature block.


    Shuttle acrylic in progress.


    Shuttle bottom panel with recessed magnets.


    Shuttle test fitting panels.


    Shuttle with lights installed and light blocking in progress.


    Rear docking port in progress.


    Sled lighting in progress.




  9. RPF Premium Member vectorzero's Avatar
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    Mar 12, 2015, 5:05 PM - Re: Long Range Shuttle - Surak #34

    Defintely worth the wait. Most excellent work.
  10. RPF Premium Member DaddyfromNaboo's Avatar
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    Mar 13, 2015, 4:15 AM - Re: Long Range Shuttle - Surak #35

    Is that really a vulcan shuttle and not wonder woman´s invisible one?

    Awesome work, I am really looking forward to seeing this finished!
  11. Member Since
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    Mar 13, 2015, 3:22 PM - Re: Long Range Shuttle - Surak #36

    Thanks guys.
    The clear acrylic is hard on the eyes sometimes but the precision it has with the laser cutter is a nice benefit.
    Last edited by dbhs; Mar 13, 2015 at 3:48 PM.
  12. swgeek's Avatar
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    Mar 13, 2015, 3:57 PM - Re: Long Range Shuttle - Surak #37

    Beautiful work, almost a shame to paint it.
  13. Member Since
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    Mar 13, 2015, 3:58 PM - Re: Long Range Shuttle - Surak #38

  14. MKWJTC's Avatar
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    Mar 14, 2015, 2:17 PM - Re: Long Range Shuttle - Surak #39

    Fantastic! Model is really looking nice in clear
  15. feek61's Avatar
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    Mar 15, 2015, 8:20 AM - Re: Long Range Shuttle - Surak #40

    I love it!!!

    It looks fantastic and I too think it looks amazing clear. Looking forward to your progress updates!
  16. Member Since
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    Mar 31, 2015, 4:01 PM - Re: Long Range Shuttle - Surak #41

    Thanks for the feedback guys.
    I finished up the shuttle hulls and did a video of the lights. The sequencing is too fast but I sped it up to make it easier to see. The final light pattern will be pretty slow except the top strobe will be timed to match the movie. I don't want a Christmas lights effect.
  17. Choosy moms choose Jif™ RPF Premium Member moffeaton's Avatar
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    Apr 1, 2015, 9:29 AM - Re: Long Range Shuttle - Surak #42

    Killer work - super clean, orderly, and the size/accuracy makes this thing amazing. I hope you bring it to Geek night in November!
  18. Member Since
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    Apr 1, 2015, 8:45 PM - Re: Long Range Shuttle - Surak #43

    Thanks Jason. That sounds good. It would be nice to have this done by then.
  19. Ryan Norbauer RPF Premium Member norbauer's Avatar
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    Apr 7, 2015, 2:10 PM - Re: Long Range Shuttle - Surak #44

    This is such a beautiful project, and very interesting to be making it using acrylic rather than styrene. Did you find that you needed to account for the kerf of the laser in your blueprints to get everything to fit together properly? I am currently working on a similar prop project in acrylic on the laser cutter and haven't yet worked that part out.
  20. Member Since
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    Apr 7, 2015, 4:11 PM - Re: Long Range Shuttle - Surak #45

    Yes, I did account for the width and angle of the laser on all of the framework pieces. The pieces needed to fit together tightly enough that the 1/100th of an inch or so of the laser had an effect. I actually did a test early on cutting out a series of about 20 1" x 1/2" rectangles and pushed them together end to end to measure the resulting width. Measured the reduction in width carefully and divide by 20 to get the width of the laser beam. I then off set all of the drawings of the framework pieces larger by HALF this amount to get them to cut out exactly the size I needed. This worked pretty good. As far as the angle of the cut from the laser... There's nothing I know of to accommodate this. I used 1/8" square acrylic rod glued in along all 90-degree glued pieces to reinforce the joints and find them to be really strong.
    Unfortunately most of the surface pieces on this, especially the nacelles are composed of compound curves out of plane with one another. Getting the skins right has been mostly trial and error with the errors being far larger than the width of the laser beam.
  21. Choosy moms choose Jif™ RPF Premium Member moffeaton's Avatar
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    Apr 8, 2015, 8:25 AM - Re: Long Range Shuttle - Surak #46

    I've also noted the angle of the beam changes slightly depending on the position on the cutting bed - mostly noticeable on 1/4 acrylic... almost cuts at an angle... but it is pretty amazing the "kerf" change, depending on how you tweak speed/pulse/power. It's an art to get parts cutting the way you "need" them too some times.
  22. Ryan Norbauer RPF Premium Member norbauer's Avatar
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    Apr 9, 2015, 10:12 PM - Re: Long Range Shuttle - Surak #47

    moffeaton said: View Post
    I've also noted the angle of the beam changes slightly depending on the position on the cutting bed - mostly noticeable on 1/4 acrylic... almost cuts at an angle... but it is pretty amazing the "kerf" change, depending on how you tweak speed/pulse/power. It's an art to get parts cutting the way you "need" them too some times.
    Yes, your beam will be focused right at the surface of your material (assuming you focused properly), so on thicker pieces I believe you'll get an upside down V shape to the laser beam's profile as it goes out of focus toward the bottom of the material. I believe it's just a matter of the optics involved rather than necessarily an issue of the position of the bed (though of course misalignment there could also introduce problems).
  23. Member Since
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    Jun 27, 2015, 7:47 PM - Re: Long Range Shuttle - Surak #48

    The top and front of the sled are done except for some of the side panels. I made a video of the lighting.

    https://youtu.be/yy0oCtAERSE
  24. Member Since
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    Sep 1, 2015, 12:58 AM - Re: Long Range Shuttle - Surak #49

    Update on the sled

  25. Ryan Norbauer RPF Premium Member norbauer's Avatar
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    Sep 13, 2015, 7:19 PM - Re: Long Range Shuttle - Surak #50

    In case you haven't seen this photo:

    Click image for larger version. 

Name:	surak.png 
Views:	59 
Size:	1.50 MB 
ID:	528191

    https://archive.org/stream/starlog_m...e/n31/mode/2up

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