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1. Having said that here is a top ten of popular Dalek variations to get you started Top Ten The whole Dalek The Imperial Daleks in Remembrance of the Daleks are of an entirely different build They are slightly narrower and have their collars moulded into the shoulders The Daleks from the 2005 series have totally different shoulders along with a host of other differences The base Film Daleks and TV Daleks in Invasion Earth have larger fender style bases Also standard bases tended to get taller in later Dalek stories Shoulder slats Early Daleks TV and first film do not have mesh or slats around their shoulders just simple collars eye stalks These vary dramatically throughout the whole of Dalek history Film ones are often longer than TV ones and the number of disks and the design of the iris changes too Dome lights Bulbs drinking beakers egg cups and beehive style car lights have all been used 6 Gun Larger bore on film Daleks and sporting octagonal mantles on early TV Daleks not to mention special projectile weapons guns used in the 1970 s For the latest Daleks the gun has become angled and chunky Neck struts They have a clover leaf cross section on early Daleks but simplify into straight round struts on later Daleks They develop corners and little blocks on the 2005 design Plunger arm Any number of different plunger sizes and2. Some builders may consider the 4 eye stalk 12 Shoulders 20 Collars fibreglass construction of the dome a 5 Eye disks 13 Shoulder mesh 21 Skirt little daunting as the first step in Dalek 6 Eyeball 14 Slats 22 Hemispheres building In this case start with an 7 Iris 15 Gun box 23 Base easier section Pick a section that you 8 Neck Mesh 16 Ball joints 24 Fender feel comfortable with given your expertise and the tools materials to hand Once you have made a good job What flavour Dalek should I build De changed throughout their BBC and film history Some of the obvious changes are the adoption and subsequent removal of large fender bases and antenna dishes The variations range from these major changes to smaller more subtle alterations such as the number of disks used on the eye stalk This document isn t about comprehensively listing these changes it is simply here to help you with the mechanics of putting the thing together it is up to you dear builder to do your homework of one of the easier sections you will feel more confident at attempting something a little more adventurous Don t feel that you have to follow these instructions to the letter improvise and if you can think of better ways of doing THE 2005 DESICON Above The plans currently available from Project Dalek SAFETY Dalek building requires a varied number of tools and materials It is essential that the manufacturer s instructions
3. a blank stare with no pupil replaced with a pyroflame arm or seismic detector 32 PREVIEW VERSION The author s Dalek created using the techniques detailed within this guide I hope this guide has been of some use to you and I wish you many happy hours of Dalek building Remember be careful stay safe and always know where your hands are in relation to that blade John Darley This guide has been produced for anyone wanting to build a Dalek for their own personal use It is not this guide s intention to encourage any commercial activity regarding the selling of Daleks The Dalek name and image B B C Terry Nation 1963 At the time of writing the BBC copyright for the licensing and selling of the full size Dalek form is held by This Planet Earth Ltd Crewe Cheshire This document 2006 John Darley All rights reserved 35 PREVIEW VERSION
4. design are not suitable for splitting These bases should be constructed as complete units bolted to the skirt once both sections are complete For a standard Dalek base you will need a large piece of 18mm MDF for the main base structure The perimeter should be marked out and cut using a jigsaw Remember measure twice cut once You will also need an inner hole cutting through which your feet can go in order to propel the Dalek into unsuspecting crowds When deciding on the size of the inner hole consider the positioning of the wheels and the seat frame you need enough board left over to accommodate these essentials If in doubt leave the inner hole until last when the wheels and skirt are in place Using further strips of 18mm MDF double up the depth of the base edge by attaching a layer of strips to its underside This will give you 36mm which should be enough to attach the rubber to If you wish to build a Dalek with a further rebated underside like the imperial kind add a second layer of wood to the desired thickness stepped in from the previous layer Movie fender bases are more difficult to construct due to their curved edges The top of the fender should be made first from MDF ply using a jigsaw to cut out the basic shape The curved edges can be made by building up layers of wood underneath the top section These should be glued and screwed together Once the basic shape has been achieved the curved edges can be made by sa
5. Version 6 0 May 2006 Preview sample only BUILDERS WORKSHOP MANUAL This document is subject to copyright Unauthorised sale and distribution in any format is strictly prohibited www projectdalek co uk www forum projectdalek co uk www projectdalek co uk 2 PREVIEW VERSION WANT TO BUILD A DALEK Well here s how These guidelines are intended to give newcomers a general idea of what materials and techniques are required when building a full size Dalek using any of the plans currently available from Project Dalek The bulk of the measurements are given in imperial sizes This is because Daleks were originally designed using feet and inches and these measurements often don t translate well into centimetres You will find that the plans booklets for the 1960 s Daleks both TV and movie are presented in inches whereas the plans for the 2005 Series Daleks are in centimetres Centimetres have been used on the modern Dalek plans as they are most likely to have been used during construction of the new props For many years the most popular plans were the ones published in the Radio Times back in 1973 While these are a good starting point they are often inaccurate and should be used with caution Building Daleks is a serious business and there are many issues to consider Before you jump right in and start building it is important to do plenty of background research We all have our favourite Dalek story and mo
6. are always followed Protective clothing masks and goggles should always be used when there is any danger of injury Also some of the materials particularly fibreglass should be used in well ventilated areas Keep stray family members and pets well away from materials and situations which may cause them harm Never use professional spray paints without the recommended safety gear Some paints are useable with masks whereas others particularly two pack paints require specialist breathing equipment Misuse of these paints can kill so please be careful If things aren t going to plan put down the chainsaw or whatever you are using and go and have a nice cup of tea Problems are often easier to overcome after a short break Remember losing your patience is only one step away from losing your fingers 4 PREVIEW VERSION mm m something or you have other materials that are suitable use them Remember above all Dalek building should be fun Essential tools Jigsaw electric drill hacksaw hammer chisel mallet screw drivers tenon saw files assorted clamps workbench vice hole cutting set Recommended tools Circular saw scroll saw band saw router electric bench drill press electric sander electric cordless screwdriver hot glue gun staple gun Luxury items wishin Air compressor radial arm saw vacuum forming table welding equipment sheet metal guillotine
7. building which you may wish to considers after you have gained a little experience Later we ll take an in depth look at fibreglassing techniques First lets look at motorising the Dalek by adding the running gear from an electric wheelchair Part 1 Motorisation What bits do I need Purchasing a complete second hand chair is by far the best option when looking for the parts you require A complete chair is guaranteed to have all the parts and if the batteries are good it can be seen running before you part with your hard earned cash Second hand chairs with good batteries are few and far between The batteries are so often degraded due to either age of lack of charging use Whatever price the chair is always budget for new batteries If the batteries with the chair turn out to be serviceable so much the better I ve got my chair now what It is possible to actually fit a whole chair assembly into a Dalek This is best done when you are building the Dalek around the chair as opposed to retro fitting an existing Dalek This has been done successfully but it is not easy and can cause headaches when trying to find suitable mounting points for the base skirt section If you are aiming to just build around the chair then its basically a case of using whatever mounting opportunities your chair has to fix the Dalek in position Remember that all that metal work does add weight to the finished article so if anything can b
8. coat they needn t be as thick on the final Dalek sections Section 11 Colour and detail quick reference guide Story The Daleks a k a The Dead Planet The Mutants Story The Dalek Invasion of Earth Story The Dalek Invasion of Earth Silver and bare aluminium with a grey shoulder section Slight detail changes including a choice of black or silver eye ball and This is the Saucer Commander complete with alternate black and Note the lack of slats and mesh plus the number of eye discs the addition of larger bases and a rear dish silver panels and a black dome Minin ji j E M i i Story The Dalek Invasion of Earth Story The Chase Story The Chase The Dalek Supreme with black dome shoulders and skirt Original The first story to see the appearance of mesh and slats Also the first The Dalek Supreme regained his grey shoulders A darker blue was also dome lights and gun mantles are still in situ appearance of egg cup style dome lights used for the hemis from this story onwards Story Mission to the Unknown a k a Dalek Cutaway Story Mission to the Unknown a k a Dalek Cutaway Story The Daleks Master Plan Silver Dalek as per The Chase complete with three part plunger arm The Dalek supreme wasn t updated from his Chase livery and like all Standard silver and grey Dalek In some scenes the plunger arm was which remained until the 1970s previous Daleks had
9. e removed steps leg plate etc then remove it Most Dalek builders will opt to strip the chair down completely and just use the electrical items This makes it easier to build a chassis for new Daleks and is absolutely essential when retro fitting into an existing Dalek Note It is next to impossible to retro fit a full working wheelchair into an existing Dalek Battery box Joystick unit Control box es Drive wheels Motors gearboxes T A _______ Front wheels Make a note of which plugs go in which sockets as you disassemble the parts get these connected up wrong later on and you could end up going backwards or in circles Under normal circumstances it shouldn t be necessary to disconnect the wheels from the motors however some chairs have small brackets for kerb lifting etc which are mounted between the motors and the wheels Removal of these can sometimes mean that the wheels have to come off in order to access the fixing bolts If you are lucky enough to have the user manual for your power chair there is usually information on wheel removal and replacement contained therein If you are working blind then you may have to poke around to find out how the wheels are fixed in place The usual method of wheel attachment uses a large nut and a lock washer which stops the nut from unscrewing as the wheels turn These are normally hidden behind plastic or rubber covers at the hub of each wheel Remov
10. e the covers and asses the method by which the wheels are attached If you find a nut and locking tab assembly proceed as follows Use a screwdriver to lever the closed locking tabs away from the nut so that the nut will be free to turn A locking washer will usually have an arm bent up over one of the flats of the nut and one bent in the opposite direction gripping a recess in the gearbox body 27 PREVIEW VERSION Motivation Daleks are fun to play around in but after a while they can make your leg muscles cry for mercy It s at this point that many Dalek builders look for salvation in the form of motorisation An ideal source of the parts you need to motorise a Dalek can be found on that robot wars favourite the electric wheelchair Those electric buggies that you often see in the streets and in supermarkets are less than ideal for Dalek use This is because of the method used for steering the vehicle which is usually done by turning the front wheels via handle bars This sort of setup is going to make a Dalek difficult to manoeuvre and also tie up both of the operators hands An electric wheelchair is usually controlled by one small joystick The steering is achieved by the rear drive wheels being turned at different speeds For example when the joystick is pushed left the right hand wheel turns faster than the left and wheel causing the chair to turn in the desired direction This has t
11. eparate unit or build the skirt up onto R it If you intend to do this you may wish to consider splitting the base skirt b for ease of transportation In either case the base should first be made up as one section and then cut if necessary once completed A cut base can be joined back together and the two skirt halves built on top in the usual way refer Sitting down Some would say that the whole point of having a Dalek is to get inside it and threaten lesser mortals with imminent extermination This is best done from a seated position so you must add a seat to the inside of the skirt Four vertical timber struts should be run from the top of the frame to the bottom and be firmly secured These are positioned near the rear of the Dalek leaving enough clear space to insert hemispheres if needed Now work out the height that you want the seat to come to Sit on an adjustable office type chair and move it up and down until your feet can wheel it around the room we ve all done that before haven t we This is the height that your seat should be set to Cut four further timber struts to this length and drill bolt them to the sides of the other struts you just fitted so that a seat base can be slid in on top of them round edged kitchen worktop is ideal Secure the seat base to the long uprights with right angled brackets If you are adding a Poa base section it may be worth considering the attachment of the seat to th
12. he additional advantage of allowing the chair Dalek to be able to turn around almost on the spot without needing forward motion to help with the turn an effect that is ideal for genuine Dalek manoeuvres Power chairs come in several different makes shapes and sizes The most modern chairs will run of 24v DC electrics These 24v motors are the kind you need for adding motive power to your Dalek In general terms the bigger the motors the better Most power chairs which are designed to carry adults will happily pull along an average size human in an average weight Dalek Some of this depends on how heavy your Dalek is If you have already built a Dalek and made it out of heavyweight materials you may cause the motors to struggle If you are scratch building the Dalek onto a motor assembly it is worth bearing the weight aspect in mind choosing materials carefully Bits to keep Motors complete with gearboxes wiring and wheels Control box Joystick box Battery boxes Seating upholstery Associated cables If this is not enough to prize the sections apart you will need to use small wooden wedges The wooden stirring sticks you can buy from automotive paint suppliers are ideal for this In the case of the dome a stick can be introduced between the mould and the plug or mould and final dome and then gently tapped until it curves around the chamfer all the way to the top of the dome The wood is th
13. he holes for the tubes can be tricky Wrap the sphere in masking tape to protect it then clamp it firmly in a drill press before attempting to cut the holes Run the drill on a slow speed using a metal cutting hole saw Cool the surface with oil as you gradually cut through Make sure you get both holes lined up or your arm will be wonky The 2005 series plunger is a far more Shopping list 3x 2x on some Daleks different thicknesses of aluminium tube see your plans for exact specification Wooden pole PVC tape P40 car body filler Can of expanding foam filler A plunger preferably a hemisphere not bell shaped Plunger screwed to inner pole Wave it about What you put on the end of your Dalek s arm will depend on which style of Dalek you are building Most Daleks have a standard plunger attachment while some Movie Daleks have a claw Other specialist arms have also been used from time to time including a cutting torch and cutting claw Do your Dalek homework to find out more about these custom attachments Although the plunger is the simplest solution modern plungers are often the wrong shape bell shaped You may have to hunt around the shops to find one with a reasonable shape and diameter If you have an original plunger from the 1960s or 1970s let me know to Section 4 The large fender bases used on Movie Daleks MK2 Daleks and the base section on the 2005 series
14. her than the back of the outer tube when the arm is fully extended enough to provide a control handle The outer end of the wooden pole provides a good surface on to which the plunger can be screwed This also prohibits the inner tube from being fully pulled through the outer tube when the arm is retracted If available a longer length of aluminium tube may also be used In this case take care with the measurements when cutting the thinnest tube The end of the tube can be plugged with a wooden insert or a nut can be glued into position ready to attach the plunger To make the ball joint follow the instructions in Section 4 on building a hemisphere from P40 car body filler You will need two of these to make the ball joint Glue them together using epoxy resin and then fill and sand to a fine finish Drill a small pilot hole all the way through the ball from front to back and then increase the size until the outer arm tube can be threaded through Position and fix into place with epoxy resin Drill a small hole in the back half of the ball joint and use it to fill the ball with expanding foam filler Once dry seal the hole with car body filler or epoxy putty Milliput Prime and paint the ball joint with the appropriate colour Thread the arm into the Dalek from the inside and attach the plunger to the end If you are lucky you may be able to track down some 4 hollow steel or aluminium spheres These are ideal as ball joints but drilling t
15. hey fit together The front two panels have a distinct twist according to most plans including those available from Project Dalek don t panic this is normal Depending on the plans you are following other panels may have a slight twist too Secure the panels with wood glue and panel pins punch in the heads so they can be hidden with filler When all the panels are fitted run strips of fibreglass up the inside panel joints and around the top and bottom where the panels meet the frame This will stop the panels moving around and add great strength Fill up any exterior imperfections with car body filler If you are fitting the hemispheres from inside you must mark out and cut the holes see plans for positioning Use a drill with a hole cutting attachment and remember that the lower shoulder collar fits over the skirt by approximately half an inch so take this into account when positioning the top row of holes If you are fitting the hemispheres from the outside a must for 2005 Series Daleks which include a black ring around the base of each hemisphere you must mark out the centre positions and drill the holes through which the fixing bolts will be fitted later on Prime the finished skirt with at least three coats of primer and then sand using the methods detailed under shoulder construction Section 3 Section 5 The Base As mentioned in the previous section you have a choice of how to make the base You can either make it as a s
16. in enough and here is enough flexibility to allow it to do this On most occasions the two sections will separate If this does not happen introduce a second wedge at the other side This will almost certainly lever the two sections apart Smooth mould interior surface Separated A similar technique should be used on the larger sections introducing small flange wedges in the problem areas until the sections separate If all else fails try introducing water into the wedged gaps this will dissolve the release agent and help the releasing process Warm water is best as it will work quickly and cause expansion of the parts Once your mould sections are released you can trim away any excess matting from around the flanges and generally tidy up the edges Use a jigsaw with a metal cutting blade to trim the fibreglass and a surform or wet and dry sandpaper used wet to smooth over sharp corners Always wear a mask when performing these activities Rough interior surface The skirt mould sections after separation from the plug The mould sections should be thoroughly washed and dried before any attempt is made to use them They can then be bolted together where required and thoroughly waxed The process for producing the final parts is exactly the same as for producing the moulds Refer back to the beginning of this section for the required information The only minor difference is in the thickness of the laminate and gel
17. is rather than the skirt Be sure to take the additional height of the base into account when setting the seat height The 2005 series Dalek base 2 Locate The Plunger Arm The plunger arm is made from two or three lengths of aluminium tube The quantity depends on which era of Dalek you are building do your research and refer to your chosen set of plans The tubes are different diameters and are therefore able to slide together creating the desired telescopic effect First of all cut the tubes to the correct lengths and then tidy up the cut surfaces You now need to bush the tubes so that they don t rattle or fall apart when extended This is done by adding layers of PVC insulating tape to either the inner or outer surfaces depending on the tube see illustration When the tubes are assembled a plastic cap should be added to the end of the large tube cut a hole in it s centre for the pole to pass through Any suitably sized bottle cap will do a good tight fit is desirable This stops the inner tubes from pulling out backwards Further bushing may be required where the tubes connect depending on the style of Dalek Small washer shaped disks made from wood plastic or metal are ideal for this Bush outer Bush inner D edge of 2nd tube Inner wooden pole edge of 2nd tube Plastic end cap The inner most tube needs a wooden dowel threading through it which extends a little furt
18. nding back the built up areas using an electric sander The sides of the fender can then be made from either wood or rubber sheeting depending on which style of Movie Dalek you are making 16 PREVIEW VERSION complicated assembly In order to create it you will have to use a hemisphere made from a stiffer material not rubber The various detail parts can be cut from flexible plastic or card glued on to the inside and outside surfaces The disks to the rear of the plunger and the plungers rim can be made from wood or plastic glued into position The completed sucker should then be filled sanded and painted black Note that this style of plunger has detailing on both the inside and outside of the suction cup The Movie Dalek claw can be made quite easily from MDF Cut the two basic sections out with a jigsaw and then sand them to a smooth finish In order to make both sections identical clamp them together one over the top of the other when sanding the edges The rest of the mechanism can be made from off cuts of steel or aluminium fixed with couple of pivot bolts A working claw can be produced with a little extra effort by adding two flat springs to the rear of the central pivots these push the claw into the open position Pulling back a central rod inside the arm closes the claw 20 PREVIEW VERSION Section 10 Advanced Dalek Building This section covers the aspects of Dalek
19. re often than not wish to create our Dalek to that specification and colour scheme Memory tends to play tricks so try and find as many pictures of your Dalek type as you possibly can This will give you a good idea of what build variations you need to watch out for If you haven t already please join the Project Dalek Forum see page 2 for the web site address You will be able to obtain the plans shown below as well as lots of help and Contents When building a Dalek it is best to break it into sections Construction will be covered one section at a time starting at the top and working down Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Dome page 6 Neck page 8 Shoulders page 10 Skirt page 14 Base page 16 Appendages page 18 Section 7 Finishing Off page 23 Section amp Painting page 25 Section 9 Ring Modulators page 26 Section 10 Advanced page 27 Section 11 Colour Guide page 32 Materials for each section are listed within that section in order to keep things simple It is recommended that readers should familiarise themselves with the construction methods listed in So which bit is that then l si ot information Our members will be only too happy to try and help if you get stuck all sections before starting to build their 1 Dome 9 Neck struts 17 Gun Dalek 2 Dome lights 10 Neck rings 18 Plunger amp arm 3 Eye cowl 11 Neck blocks 19 Claw
20. shapes plus the addition of claws on some film Daleks Also the number of telescopic tubes changes from three to two on some later Daleks 10 Gun box design Some gun boxes slope backwards some are level Later ones have an oval plate between the two ball joint holes 5 PREVIEW VERSION The Skirt Part 3 Panels Skirt panels should be made from thin wooden sheet 4mm MDF is ideal though hardboard or other materials could be used Try to avoid wood that has a grain as this will be difficult to hide when painting the skirt later on If your plans give individual panel dimensions use these but double check before cutting If you don t have a set of pre defined panel shapes don t panic proceed as follows Working one panel at a time cut out a slightly over size rectangle then lie it against the skirt frame so that it covers the whole area that the final panel will cover Clamp it into place then using a pencil and ruler draw lines on the back of the rectangle starting at the top corners of the frame and ending at the lower corners Repeat this for the horizontal lines so the final shape of the panel is marked out on it s rear Cut the panel and test fit it Remember the sides of each panel will need to be cut with or sanded to an angle or cut in order for the next panel to butt up to it snugly It is recommended that you only fit a panel when you can offer up each adjacent panel to check the way t
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