|
Construction Notes |
|
The
Dome Cowl
|
| This was
made up using the dome plug (before making the
dome mould). A layer of cling film was stretched
around the dome so the plaster could be added
without sticking, then 4mm MDF was cut and
shaped and fitted to the plug using masking tape
to hold it in place. |
|
|
| A former
made from styrene sheet was placed around the
dome to form the outer shape of the cowl, and
this was filled with P40 fibreglass filler and
sanded to the required profile. |
| |
| Once
removed from the dome plug, the underside was
sanded smooth and the whole casting was given
two coats of G4 sealer and sanded with 600 grit
wet & dry, before being given a black basecoat
and clear lacquer finish. |
| |
| It was
originally intended to make this from
fibreglass, but it gave me a headache trying to
figure out how to make the mould so I left it as
it was. |
| |
| The cowl
was loose fitted in position on the dome
casting, and the slot for the eye marked and cut
out. |
| |
| The cowl
is held in place on the dome with 20mm coach
bolts - these have been lacquered to prevent
rusting. |
| |
|
The
Dome Lights
|
| The 2005
series Dalek dome lights are a long way from the
Land Rover lenses of the 60's & 70's Daleks, and
these were made up by modifying a pair of
Moflash SF126 signal units. |
| |
| The
position of the lights was marked out on the
dome casting and cut out with a hole saw. The
bases were installed in the dome and epoxy resin
glued in place. |
| |
| The
polycarbonate lenses were modified using
fibreglass resin and plasticard 'cages' - The
lens bases were made up from coffee jar lids
(Nescafe of course) |
| |
| The lids
were cut to fit the outer diameter of the
lenses, and 0.5mm plasticard strips were cut and
glued to the lid to produce the outer ring and
top trim. |
| |
| The top
ring of the lens cage was made up using 2.5"
plastic fallpipe sections glued together and
profiled to fit in place. an RTV flexible rubber
mould was taken and casts were made in
resin. |
| |
| The
cages' vertical slats were formed using hardwood
patterns and making a rubber mould - casts were
taken, trimmed to profile and fixed in place
with epoxy resin. |
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Go to Part 3
- Eye & Eye Stalk |
