The Challenges of Building a Dalek: Part 10
Be sure to read the previous parts of The Challenges of Building a Dalek. Picking up from where I last left off, we have a lot of projects all happening at once. As we have started to form foam to create the mold for the dome; we are also making five latex molds so we can start casting the balls in resin.
Dome Mold
In order to make the mold for the dome, we have to create the inside first so that we can get the perfect shape. These are about the same steps we were having issues with the first time around; the issues were so bad that we put the project on hold for years until now. The inside has dome shape cross beam that is our guide. Each section will be filled with multiple foam board/insulation foam layers. To cut the foam in the desired shape we have to use a hot knife, as dad likes to think of it as one step below a lightsaber. Using the hot knife, we are able to get the curves that are needed for the dome. Between each layer of foam board, we use gorilla glue to glue in each layer.
Hemispheres
Hemispheres are the half balls that surround the lower half of the dalek; in the show, these half balls were originally used to house the armor’s primary sensor system, electronic warfare suite, and communication array. For us and the use of our dalek, it’s for decoration. We originally were going to use styrofoam balls, but after painting one we noticed that the ball began to bubble and just looked horrible. After talking to other dalek builders, they suggested making a mold and then using resin to make the half balls. This is something neither of us has played with, resin and latex.
After making the first mock mold, which surprisingly didn’t turn out bad, we took note that it needed more gauze and layers to make the mold stronger. Applying our newfound knowledge, we applied to the second mold and it came out exactly what we needed. So now we start the processes of how to resin, we bought a basic starter kit and tested the resin in the first mock-up mold. While that is setting, we start the process of making three mold molds; so that we can cast four balls at the same time so that the color will be equal. Because these are rounded shapes, dad had made a stand to hold that molds as they set with resin.
Current Design
Currently, the neck is about 10 inches in height; and about 16 inches in diameter. When you add it to the base it stands at 62.5 inches, 1587.5 millimeters, including the wheels. We are in the process of looking for another electronic scooter/wheelchair to make the next dalek to make more of today’s version of the dalek.
