The Challenges of Building a Dalek: Part 11
Be sure to read the previous parts of The Challenges of Building a Dalek. Picking up from where I last left off, we are still working on the hemispheres as we have come across a few issues in how they cosmetically look. Hemispheres are the half balls that surround the lower half of the dalek.
Hemispheres Molds
In the previous part, I mentioned how we were making latex molds for the resin half balls. But after our first attempt, we noticed there was something wrong/off about the ball. We noticed the ball had a lot of indents, imperfections, a cloudy complexion, and just looked not right. So, after talking to one of Fandemonium Networks’ writers, Jenn, we found out we needed to make the molds out of silicon and pour the resin all at once. She then gave us strict instructions to follow when making the resin and even told us what brands to buy.
So, after buying a silicon ball mold that splits in half, we followed the instructions that were given to us and put in the black ink just right. We finally got a somewhat decent-looking half-ball; seven attempts later we now have perfected it. We have learned a set of techniques to make sure we limit the number of imperfections, but on occasion, we do get air bubbles; dad is calling them battle wounds and the odd-shaped ones will be put to use as paperweights for our friends/family.
We will be making another silicon mold so we can have two going at the same time; also, when we eventually need to use the ball mold to make the balls for the gun mounts, that way we are not stopping the production of the hemispheres.
Dome Mold
We have finished filling the shape of the dome with thick layers of foam board, now it’s time to actually make the negative mold before we can make the positive mold out of fiberglass. To make the negative mold we are using finishing plaster as per the instructions in the blueprints. In order for it to dry correctly without cracking, which has been our problem in the past, the plaster needs 24 hours to dry with each layer of plaster. So, this step will take a few days. This is the step we are taking the most precautions on, as in the past when we have attempted to make a dalek our mold kept cracked, after multiple attempts and methods we had to put the project on hold until now.
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. Derek the Dalek is currently a bright hunter green and will be having soul-sucking black hemispheres around the base. 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.
