The Challenges of Building a Dalek: Part 12
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 still have a lot to make, we are also still working on the negative of the dome mold. Hemispheres are the half balls that surround the lower half of the dalek.
Hemispheres
So, we keep encountering casting issues when we attempt to make more molds to make more hemispheres. Every time we make one, for some unknown reason it cannot come out right; even though we follow all the steps in the correct order and buy all the correct items; it just doesn’t come out right. So, we have given up making our own mold and purchased premade ones from amazon, as the price for a premade one is a whole lot cheaper than making our own.
We are also having issues with certain types of resin, as they seem not to be mixing or setting right, leaving the half balls with a sticky top, deformed, or horrible textures. Because of these texture issues, we are attempting to polish and smooth the troubled textures of about nine balls. The balls with the sticky tops sadly cannot be used or salvaged, but we will be using them as tests for the next steps; which include how to install them and how to drill in the necessary screw.
Dome Mold
Dad thinks he has figured out how to stop the plaster from cracking; you have to use drywall tape in short pieces like papier-mache. The drywall tape acts like a bind as it would for drywall. There are about three thin layers of plaster; we have learned that making each layer thin gives us more control over how it dries. The worst-case scenario is the plaster crack because if that happens, we have to start the dome process from the beginning. This is also the longest process as you have to wait for each layer to dry and that takes about 24 to 48 hours.
Once this plaster mold is done and smooth, like glass, this now becomes our negative to make the fiberglass dome. We did find out from the dalek builders that you can buy one already made, but it may not be to your size, they also suggested once you have it done and in great condition; you can use the plaster mold as many times as you need.
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.
