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20 July 2019

  • John K's Next 60s Dalek (jk4)
    I'm making another 60's Dalek, pretty much with the same criteria as I made my first one; -as far as possible I should match the materials, design and build technicalities as Shawcraft themselves used in the 60s. -I can mix and match authentic design elements as I fancy, this is not meant to replicate any specific Dalek from the 60s. It's going to be another Power/Evil type, and I'll be going over much of the same ground, so in this thread I'll only focus on new things.. and the first new thing is that I have decided is that I'd like to make a Dalek with wooden antennae boxes! I decided that I should finally make up my own shoulder mould for this, so took one of my casts with gunboxes, chopped the boxes off, sanded down the rough bits, put plasticard over the holes and then fibreglassed patches in. Easy to type, ages to do. The cast I worked from is exceedingly authentic, but clearly has been painted, bumped, knocked, chipped and sanded numerous times over the years. So, I decided do remediate these problems as far as possible. I used P38 filler, Durabuild surface primer and Halfords Hi-Build Primer in various combinations, along with a lot of wet and dry sanding. I started with 60-grit and worked up to 2000-grit for a nice smooth finish. Afterwards, I cleaned it with degreaser, built up the mould dividers and supporting structures, filled gaps with plasticine, then applied five coats of honey wax. Oh, almost forgot...before I did all that; the other thing that bugged me was that the shoulders were not exactly flat, top or bottom, nor were the top and bottom precisely parallel. To this end, I cut wooden 1-inch square wooden pieces of various thickness and using a spirit level and wedges, glued these strategically to the top and underside of the shoulders so that it sat level on a flat surface. I then painted some gelcoat in the appropriate shape onto a flat melamine faced board, then sploshed resin mixed with choppies all over it. I then squished the bottom of the shoulders into it. Let that cure, released, then repeated the same process to the top. Then the tedious sanding and filling... Result; a level set of shoulders with about 5mm extra height (which is easy enough to lose when trimming the casts in due course). Moulds should always be a different colour to the casts you are likely to pull, so I wanted to find a colour that I would never, ever cast up a piece in. So I got some RAL Telemagenta pigment. It's shocking. But oddly delicious looking. Thus far, I have applied two layers of gelcoat and the first layer of re-inforcement. Elsewhere, I have already made a mould for movie shoulders, that I intend to use for a Genesis style Dalek in due course. I'll create a thread for that once it picks up steam.
  • Leblanc42's NSD
    Good afternoon all, I've just started a build after months and months of sleeping on it. We will see if I have the skills necessary to pull this off! 1st step building the lower platform and skirt frame done!! Now I just have to stay on track.
  • Dalek Viper
    Look at my dalek viper, sorry for the drawing, it is based on the probe droid robot, the structure is dalek 2005, mk2, mk6 and the shadow dalek and ideas to put led logic and head of the R5 D4, was based on B9 and R2 D2, its dome rotates automatically, torso also rotates automatically independent of the dome, its armament and claws, probes etc. they are embedded in the left side weapon box. It's cylindrical based on dalek evolution 1, it's spy, crawler, explorer and killer, all in my dalek. The project is still on paper, so I'll be posting photos of it soon.
  • Tdb30_ NSD Dalek Fuzzball
    Never had a build diary before. I'm going with gusto on this build after a 10 year hiatus. This is the current status. I'll try to dig up the old photos and do an update with them.
  • Bob's Planet Dalek - Seven 2 (loosely)
    Hi All Just a quick 'hello' before I start posting pics of my build. I have wanted to build a DW prop for years and years, lurking around various websites such as this one but never quite getting round to it. Then last summer I finally scratched an itch I’d had for literally decades, by constructing a K9 (I sent a pic in recently to DWM and they kindly published it, so you may have already seen him). I had no prior experience in such a venture, so it was a steep learning curve but I found the whole experience exhilarating. I haven’t been as ‘into’ something as I was those few months in 2018 and K9 is now part of the family. Having caught the bug with K9, I wanted another taste of the fun, so I have decided to build a Dalek. With limited space and funds, and a plan to move next year I have decided to build it in stages, with the shoulders and possibly neck this year, and the head and skirt/base next year. My preferred shape and colour scheme was always the dark grey flavours of the 70’s and 80’s, along with the Necros and 2005 machines, but after much mulling I decided to go for something that approximated Dalek Seven 2 in Planet of the Daleks. I really like the extra depth of colour that the metallic paint adds compared to say a Genesis machine. They really look smart. I cannot overstate how helpful it has been looking at other peoples builds to get an idea if I’m on the right path or not, and to learn from other peoples experiences. I hope I can do the same here, as far as I am able (as a rank amateur) So, I have started with the shoulder frames and I'm currently finding the gunboxes tougher than I expected, so I have the basic frame assembled from 12mm MDF. I have also started to tinker with the balls. I originally bought a pair of the steel 'gazing' balls that I have seen talked about, and bought a couple of hole cutters. Unfortunately, my drill and workbench simply weren't up to the task and barely dinted the ball (before they skittered off onto the floor). For my second try, I ordered a few of the Christmas baubles, also mentioned on here. Sadly, these too were'nt quite right - they shattered when drilled and just cracked when I tried to cut them with a knife. Ultimately, some searching on Google presented me with a company that was happy to sell small volumes (but quite pricey) polypropylene balls of the right size. These seem spot on (see gun test fit below). They can be cut easily with a scalpal to size and conveniently have dots to identify the centre to cut around and are sturdy. If anyone would like details of the company in question, shout. They set me back around £20 for 3 including postage (which was next day). I assembled the 'ball holders'. I don't own a router, but I plan to borrow one for the neck rings, so I used the tried and tested method I have seen used on these boards, of using one of the now unused steel balls with some coarse glass paper wrapped around it. I then finished off with my sander mouse. This seemed to do the job when I test fit with the balls, and I will also add some felt around the inner recess. Tha aluminium oval is actually the first thing I made, using the template on here and 1mm sheet. I used my jigsaw to cut it out and plenty of filing and sanding. Easier than I was expecting.
  • Ethan's Custom NSD
    Hey everyone! Recently decided I was ready to build my first Dalek after multiple times of thinking I couldn't do it. I am wanting to make a combination of the more classic Daleks, combined with the NSDs. I'm thinking toward using the color schemes that were used for the original Black supreme Dalek and throw in a couple elements of the past design(As I absolute love them) along with the NSD type build. I'm really excited and I hope anyone who sees this I can give and as well receive ideas of new or useful ideas of how we can create what we love so much! I will begin posting photos and updates tomorrow and throughout the week!:)
  • Genesis Dalek
    Hi. Started work on my first dalek built this week. I've got two more panels to fit, then lots of filling and sanding to look forward to. Very pleased with how it's going so far.
  • John Hogg's Dalek
    ok so nearly finished my biggest restoration project yet, sorting photos out soon , now my Daleks story, i bought him from a well known local Dalek builder, though i did not know when i bought him at the time we had already met ,so the poor dalek was an abandoned project ordered and then cancelled,he had lived a lonely life abandoned and forgotten for a few years gathering dust cobwebs and a few other hidden visitors,he looked ok from a distance but was made as a static prop so just needed tarting up, i then decided to do a full restoration from head to toe this will be my story and journey taking nearly 2 yrs in between work and living three up in a flat with limited tools
  • Forty's Invasion Mk2
    I have been planning on building a dalek for a long time but have been unsure on where to begin and occasionally a little unmotivated. Before I begin any advice would be greatly appreciated.
  • Ted's Dead Planet Dalek
    Hello, Almost two years ago I decided to build a Dalek despite having very little money to spend on it and next to no experience. I had a lot of help from neighbours and relatives though. It started off well; In the first month I managed to build the gun, eye-stalk and plunger arm with the skirt being constructed about a month or two later. Shortly after this, the project was set aside due to schoolwork and some personal issues. I started with the gun which was made using parts from my local B&Q. The central tube and the rods were all made from steel so the gun is quite a bit heavier than I anticipated. The rods were bent using an old pipe bending press my neighbour had in his garage: The three octagons were made from laser cut acrylic with the strut detailing being engraved onto the surface then painted: and here is a close up (kind of): The collars were made from plastic PVC pipe joints that had the inside expanded to fit over the steel tube. They slid over the tube with a very tight and secure fit. The rods were attached to the collars and the octagons with two-part epoxy glue. The collars were hand painted with silver enamel paint. The firing mechanism is loosely based on the one from the 70's instead of the 60's claw like design. It was made from an old paint brush, a knitting needle head (which I want to replace with a small ball), a spare steel rod and a drinks can all held together with epoxy glue and candle wax. I used candle wax to hold the leaves in place because I needed them to be easy to remove as I intend to replace them with something neater later on. The eyeball was made from a magic 8-ball and a disc of plywood: The discs were laser cut from clear acrylic then spray painted blue. I won't fix these in place as I hope to buy the re-manufactured 60's blue perspex from here. It's a little rough around the edges and, again, this is something I hope to replace in the future. The stalk is just a steel tube with no taper. I would like to add a taper to it but I have no idea how to go about it so, for now anyway, it will stay a straight tube. The plunger I bought from Wilko. It had the same round shape as the original style plunger and had a slight outer lip: The telescopic tube was made from three of the steel pipes from B&Q. Only the innermost tube moves as the middle tube is glued in place: The frame of the skirt was constructed from MDF (this is the only photo I have of it, sorry it's so dark): The panels are made from 3mm thick plywood: some of the panels were accidentally cut too short and I definitely plan to fix this. I have bought the hemispheres but haven't done anything with them yet. They are 100mm diameter clear plastic Christmas decorations which snap together: At this point, I'm not sure whether I want to bolt the hemispheres onto the outside of the skirt of push them through holes from the inside. I started working on the shoulder section today and due to a problem I had with the plans, it was cut the wrong size. To come around this, I fixed a strip of 2mm MDF hardboard to the outside to make shoulder base slightly larger. Its not a perfect solution but it should be OK. I don't plan on continuing until my workshop manual arrives. That's all I have built so far. I'll keep this thread updated. Thanks for reading.
  • Tiriki's NSD
    It's been a few weeks since my two boys (Tiriki 9, and Jarahyn 6) and I had finally got around to starting our build. We talked about it for a while and settled on a NSD, primarily because it seemed a little less confusing. We ordered the project manual and waited for that to arrive before cracking into it. Starting out with the dome, we headed off to Bunnings and picked up all of the materials we needed. We built the form work, using the downloadable template, simply gluing it to the plywood, before cutting it out, rather than bothering to trace it. The only slight pain with that was the paper getting gluggy and peeling off in bits as we swept the former around the plaster plug. The plug itself has taken a while and isn't quite finished, simply because of a lack of available time (many other projects!). However, so far I'm reasonably happy with it. We built it on top of a stack of xps off cuts we had sitting in the workshop, with the major gaps covered with tape. Then the plaster went on. A few layers of this, and swinging the former around it, realising that it was best to work on it somewhere between wet and dry, since it was too hard when set, and could tear out chunks if a bit too soft. This is being followed by an occasional 10 min session of dripping a small amount of plaster off a spoon onto any tiny marks or gaps in the dome, and sanding them almost immediately. Since taking the attached photos we've removed all of the surface blemishes. I'm not super happy about how well we've defined the line between the hemisphere and the more vertical lower section, but we'll work on that once I take out the pole. One thing to note is that I thought it might be easier filling gaps just using a tube of 'fine surface filler', but that stuff is a bit softer than the plaster I used. It would sand out quicker, leaving an ever so slight depression. Hence using the same plaster, dropped off a spoon. Much easier. For a shiny finish, and release, I have some J-wax and PVA mould release, which I had anyway. I've read on here at least one person suggesting j-wax isn't a good idea. Thought? Alternatives? I've done a lot of casting, but I've not used fibreglass previously. Cheers, John
  • Kempo Imperial Dalek
    Just started to build base and panels early stages photos to follow.
  • Mark Reardon's Imperial
    Well, I’ve started on my journey of building my imperial dalek. Here are some pictures of the very early stages.

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