Joe Nagle: New Series Dalek
Before starting this Dalek, veteran Dalek builder Joe said, "I'm gonna try to make this build a bit different as I'm absolutely sure I'm not the best builder on the site (I'm a graphic designer/artist). I know how things should look and can normally get great results sometimes by an unconventional route.
This build is gonna be quick, cheap and look fantastic... For instance, my first diary posts will be called 'how to make your eye using the wife's juice squeezer' and also 'how to avoid buying Heronrib' and finally, 'how to make your neck blocks using mint skittles'.
Joe is nothing, if not resourceful!
How it was done...
For the back of the eye, Joe used an old hemisphere. The stepped front section is made from part of one of those big hand-pull chromed juice squeezers. The front of the eye (the bit with the chamfered edge) was made from part of a small nylon plastic bottle, picked up in York. The size looked perfect so that was also cut up and glued to the rest of the other parts.
The neck mesh was made using a laundry basket as a substitute for the expensive Heronrib matting. Advantages here are that it is cheap and the uprights actually taper just like the neck bin itself. The sections were given a quick sand down to produce a key for the paint, then Halfords plastic primer was used for the first coat, followed by satin black.
To make the fender, Joe drew the whole shape onto paper and just lined up the vertical side panels with the whole thing face down, supported at the correct height on four small piles of CDs! He then glued and screwed the sides into place. In between each upright side panel he cut wedges of wood which are tailor-made pieces designed to give additional strength.
For the gun and arm ball joints, Joe purchased a pair of not-quite-round 100mm stainless steel soap dispensers. They turned out to be strong but also nice and thin which meant they were easy to drill. When mounted in position, in the two wooden clamping sockets, the fact that they are slightly oval doesn't matter. They move around nicely and look round.
The slats took quite a while to fit, filling and sanding each one individually, to gain a good fit. The actual screen Daleks have clearly visible gaps between the shoulders and the slats, so Joe was happy to emulate this without filling the gaps completely as if they are moulded to the shoulders. Joe says the shoulders really tax your enthusiasm and patience, so you really have to dig in deep and persevere.
Joe cut disks from hardboard to go inside each of his vending capsule hemispheres. The disk diameter has to be just right. Too large and they don't fit in the hemispheres, too small and they go too far inside and the bolts aren't long enough. After waterproofing the disks with a PVA water mix, the bolts were glued on with a little No More Nails and a bit of gaffer tape, ready for the final painting.