Apology for the bad quality photos, this build was made in art school some when I had a very bad phone.
All righty, here's something good. First attempt at something big and bold for my portfolio. Made this in-between classes during my sophomore junior year (2015-2016) of art school. I learned a lot about electronics, fiberglass mold making, and lots of new painting techniques for this build. Plus I think I got some extra attention living in the dorms with this thing.
So here we are, Summer of 2015 at California College of the Arts. My nice little side project during my work-study job.
Skirt was made from 1/4' MDF panels glued around a 1' MDF base reinforced with lumber and later fiberglassed from the inside. The bumper was just CNCed MDF reinforced with fiberglass with a few bolts that hold the wheels together underneath, then I push it down hill, weeeeeee!!
This took me about a month and a half to get to this point. Fairly good considering I had no access to the shops over the summer. Luckily I had my grandpa's good old jigsaw! The smaller thing is a jetpack I was also working on, separate thread.
FUN FACT! The hemispheres on the sides are actually vending machine capsules ordered in bulk. I used E6000 and to glue in bolts and then reinforced it with expanding foam.
And here we are in my dorm room because only seniors get to have a studio to store their artwork, thank god I didn't have a roommate.... Here I'm starting construction of the shoulders and gun-box, using plywood as its base.
Most people use lamented wood or wet MDF for the shoulder outer skin. I had several sheets of 6mm PVC foam laying around so I ended up just using that and a heat-gun; worked perfectly. The real challenge was getting the gun-box to line up with the holes.
All righhtttt, making progress. Cutout the neck rings with a router. Starting to make the arm pivot boxes. The ball joints I'm going to end up using are garden orbs that I'll weld the appendages to. I laser-cut some covers just to make it look nice on the front too.
Alright now while that's all going on in the background here's the progress of the dome. My goal was to make a fiberglass mold so I ended up using my school's CNC to carve out the plug. Here we see it right out of the router, then after using the heck out of the palm sander. Sanded it and smoothed it with polyurethane floor sealer so it's all prepped for mold-making.
And here we are, pulled right off of the plug! I ended up cutting a pice of styrene and glueing it in the mold so I'll have a. nice little guide on where to cut out the eye pivot slit. After some waxing, PVA, another coat of gelcoat and layers of fiberglass later, I have the dome! At this point in my life I've never been so proud of myself.
Fun fact!! My school had no rules or guidelines on fiberglass before I came around, Now they banned it !,
( Sorry underclassmen and future students.)
Working on the pully and pivot system for the operator. Nothing too fancy literally just wheels turning the head with a string and lever to move the eye stalk. Speaking of eye Stalk...
IDID'NT REALIZE HOW HEAVY THIS THING WOULD BE., reminds me of this photo of someone finding a dalek in the lake.
Okay just fooling around with some test electronics here. This build also doubled up as a class assignment for my interactive class. Was learning arduino at the time so why not right? I have a patch running in Max MSP that converts my voice into the classic dalek voice while also changes the neopixles in the eye from blue to red.
Cool effect from the eye stalk, Used a bubbled lense from a pair of sunglasses to give the neopixles a reflection. Those eye rings are just lasercut acrylic.
So prior to this build I didn't know that the original daleks used a paint roller for thier gun arm.... Had I known that I would have just went out and bought one but no. I had to be the stubborn guy who makes everything! My gun arm is welded from pieces I found in my schools scrap bin.
Doing some last minute touch ups for an interactive electronics show. I'm adding dome remote control under glow lights underneath the bumper, you gotta go all out with the lights on this thing.
Crude setup for the interface show. Basically all the electronics are temporarily held in a toolbox which is my seat inside the dalek , hooked up to a 12 volt air compressor/ battery.
Now that that's over, wouldn't you know, it's winter break, Time to head to Chicago for a month!
PAUSE FOR WINTER BREAK
And we're back, No that I have The basic shape and structure built it's time to sand and perfect. Bondoing up all the seams on day one of arrival.
I'm making a little something extra for the neck rings, These will be on all the stalks that hold it up. I'm already mixing up design the design of this dalek from the original 60s plans so I might as well change this too. I just found a small battery on the floor while i was making the wooden block so I though ehhh why not" and super glued it on there and made a mold. Casted several of these.
I'm using Hammered burnished umber for my base coat. I want this guy to have some texture to him, I also Have no idea what I'm doing but that's where the fun is!
Neck is all ready for paint.
Top coat of metallic rust lightly sprayed over the burnished umber. I have a plan, just wait and see!
Here you can see I mixed paints. I sprayed a combination of Hammered Rosemary and Hammered Burnished Umber. It gives it a believable tarnished metal texture on top of the Metallic Rust, but I'm not done there!
Here's a fun technique. After the top coat of metallic rust was applied i softly sanded it away using 320 / 400 grit. Because of the hammered paint underneath it i gradually get a fantastic splotchy rusty texture sanding away all the high spots. This is a great technique but I wouldn't use it on smaller pieces like helmets or armor. It looks great up close ( hero great) but it only works if the area just large enough to have large chinks worn away. It looks great but it needs a patina.
Making the collar out of sheets of aluminum, Thin and strong.
I should have drilled all the hemisphere holes at once in the beginning....
The rest of the was made all the same, combinations of Hammered Burt Umber and Rosemarie with a mix of Metallic Rust here and there. The sanding really makes a difference in the texture.
I used a home made acrylic wash for the patina. I made several different shades to apply for added detail. For more textured spots I'd use a sea sponge to dabe it in. For the most part I'd just meticulously paint it on with a brush. Every once in a while i'd take an alcohol rag to take some more away.
At this point i wasn't satisfied with the neck cage so I upgraded from the original daleks screen mesh and bought some fancy perforated aluminum from Home depo, looks so mush better and it's harder to see the operator.
Kind of took over the spray painting area for the final touches of paint. Was working on several things at once. Normally I'd do this in my dorm room.
For the aluminum, collars I sprayed the rest of the hammered burnished umber , but for more detailed look , I used oil paint to whether and age it dirty brown.
Did a little update on the electronics. Instead of running Max MSP from my mac to run the voice modulator patch, I'm using pure Data from my Raspberry Pi III, had to do some reverse engineering on the patch in between programs but it's a heck of alot easier setting this thing up from the inside compared to using my macbook inside this small cramped space,