Dbg Nsd Plans

Issue 1- July 2008

© Steve Fletcher & The Dalek Builders Guild 2008

DALEKNEW SERIES

2005-2008

INTRODUCTION

Welcome to The Dalek Builders Guild New Series Dalek plans. It's been a long time since the Guild has produced a set of plans, so it's a big "thank you!" to everyone involved in the production of this document.

With these NSD plans, we've used CAD software to build a precise 3D model of a Dalek, and then 'exploded' that model to indicate the exact dimensions of every component. In taking this approach, we've already eliminated any conflicts or inaccuracies in the build process. This will mean that a Dalek built by carefully following these plans should look identical to the 3D projections of the complete Dalek you see in this document.

Our aim in creating these plans has been to simplify some of the construction process. It's evident that the Dalek props seen in the revived "Doctor Who" aren't entirely symmetrical -- they were built to be practical effects props rather than precision showpiece models. So, in places, dimensions have been slightly modified to give you a symmetrically finished prop. Also, unlike our classic Dalek plans, these new plans display all measurements in millimetres.

We have included a 3D breakdown of the plunger and eye-stalk, so you can see how the various components used fit together. Also, you'll find exact detail of all the EMA part numbers required, should you want to go down that route.

As we've not produced any plans for a good few years now, any feedback on these is welcome. We'd be very keen to hear your suggestions about how to make the plans even better and easier to understand.

We'd like to thank everyone for their support over the year, and hope that these new plans make your Dalek-building "bug" come buzzing back to life!

RegardsThe Dalek Builders Guild Team

Please note - these plans are subject to copyright. They are available as a free-of-charge download to members of the Dalek Builders Guild. They are not to be copied, resold, modified or distributed in any fashion.

If you have received these plans from any other location other than the Dalek Builders Guild, please contact us, stating how you obtained them. Thank you.

LIGHT CAGES

DOME

COWL

NECK BIN & RINGS

SHOULDER SLATS

FENDER

HEMISPHERES

SKIRT SECTION

SHOULDER SECTION

PLUNGER ARMEXTERMINATOR

GUN

PAGE 22

EYE STALK

PAGE 21

PAGE 20

PAGE 18 & 19

PAGE 4 & 5

GUN BOX COVERPAGE 11

ANATOMY OF THE DALEK

PAGE 23 & 24

PAGE 14 & 15

PAGE 9 & 10

PAGE 6

PAGE 6,7 & 8

PAGE 16 & 17

PAGE 12 & 13

26

1

48

74

40

41

9

22

0 37

5

24

7

25

3

48

7

THE FENDER

45°

90 13

7

47

Drawing Scale 1:12

Skirt base profile (Outside)

396

1297

292

300

255514

RE

F9

74

267

142514

145

60

642

A

B

CD

E

F

The Fender has been upgraded to give it a 'chunkier' look than TV Dalek props of the 60s, 70s and 80s. The surface is finished with a "Hammered" or "Stippled" effect, to give it a heavy, robust look.

1196

121602

835

1070

276

26

14

11

7

Plan View On Sloping Section (A)

TYP

292

68°

254

66

.5

80.4

°

Plan View On Sloping Section (D)

84.5°

513.8

481

68.5

°

Plan View On Sloping Section (E)

68.5

°

267

227.5

78.5

°

Plan View On Sloping Section (F)

78.5°

494.5

522

78.5

°

THE FENDER PANELS

Plan View On Sloping Section (B)

80.5°

300

282

84°

Plan View On Sloping Section (C)

The Fender should have Socket Cap Screws fitted; 4 on each sloping panel. These screws are not fitted to exhibition Dalek props.

These views show the plan view of each sloping section starting from the front of the Fender. Each section has a letter which corresponds to the appropriate section on the previous page. Two of each section are required, apart from (F), where only one is needed.

Some further work will still be required once the initial parts are cut out; when joining the sections together, each mating face will require mitred angles to be cut or machined to match the next section. Since different thicknesses of material may be used for the fender, no dimensional details can be given for this. It's up to the builder to modify the parts themselves to achieve the appropriate join. However, don't forget to flip the pieces (to suit the left-hand or right-hand side of the fender) before mitring!

84°241

255.1

84.5

°

The fenders on the tv varient Daleks,have Socket Cap Screws fitted, 4 oneach sloping panel, however theseare not shown on the exhibition models

M4 Socket Cap Head Screws typical positions from each edge

8

8

14

2 25

9 31

5

714

17

8 23

03

80

259

104 ID

52.50

140

94

1067

440

102

317.50

5331

78

32

0

96280158

15

0

110 OD

12

THE SKIRT SECTION

The skirt section for the New Series Dalek is based on the 1960s skirt design; it is very similar in height and shape to the skirt sections produced by Shawcraft Models for the older Daleks, as seen on the small and large screen from the 60s onwards.

56 Hemi's & SealsRequired

(15

4)

(15

4)

(10

3)

R50

10

0

Inc Seal

The skirt, like most of the other main components of the Dalek prop, is usually made from fibreglass (GRP). The first Dalek prop to be built for the 2005 revival of Doctor Who, which came to be known as "MT1" (in honour of Mike Tucker, a member of the visual effects team involved in its construction, who had previously worked on Doctor Who in the 1980s), was made up of separate mouldings for fender, skirt and shoulders, though the props subsequently built for "Bad Wolf" and "The Parting Of The Ways" had these components moulded as a single part.

The skirt section used for MT1 wasn't symmetrical; while the differences would be hard to see with the naked eye, we felt that this was one of the areas where we could modify the skirt to make it symmetrical and hence somewhat more straightforward for the builder.

The hemispheres on the NSD are bolted on to the skirt panels. Each hemi has an M8 stud protruding out and is fixed in place with an M8 nut on the inside. This contrasts from earlier Daleks where each hemi was entirely inserted through a large hole in the skirt section and then GRP'ed in place.

A new addition is an oil seal which sits behind each hemi. On MT1 these are from a DAF HGV. A mould was taken from an original seal and the 56 seals required for each skirt section then produced from that mould (probably for reasons of cost).

(12

1)

(15

4)

16

1

68

6

10

1.5

16

11

61

10

1.5

72

3

147

12

276

68

9

96

182.5

327

70

0

4

167.5

268

69

1

1

6

69

5.5

0

4

1

52

69

2.5

0

SKIRT PANEL SECTIONS

205

As mentioned earlier, the skirt section used on MT1 wasn't symmetrical, meaning that the opposite panels on the left and right sides were different shapes and mated with their neighbours at slightly differing angles. We have made the necessary modifications to make the skirt section entirely symmetrical.

280

440

258 234

177.02

167356

460

103

7491

129

84

88.5

84

117

76

76 76

76

76

76 76

76

HEMISPHERE POSITIONS(1

02

)

(10

2)

(10

2)

(15

8)

(15

8)

(15

8)

(15

8)

(15

8)

(15

8)

(15

8)

(15

8)

(15

8)

Panel 1

(10

2)

(16

5)

(16

5)

(17

8)

16

81

06

16

81

68

(10

2)

(15

8)

(15

8)

(16

5)

Panel 2

16

51

02

16

51

65

Panel 5

The dimensions here represent the hemisphere fixing hole positions on each of the flat panels, prior to assembling the skirt section. However, some builders find it easier to mark out the hole positions on a completed skirt. Please refer to page 6 for the vertical positions.

We have included two sets of hole positions for the hemi’s, we have left it up to the builder to decide what looks best for his Dalek,

Set 1 (not in brackets) are taken from a standard movie skirt, while the Set 2 (in brackets) closely match the hole positions used on MT1,

16

31

03

16

31

63

(10

2)

(15

8)

(15

8)

(15

8)

Panel 3

16

21

03

16

21

62

Panel 4

16

21

02

16

21

62

Panel 6

16

31

02

16

31

63

263.50

145

114

119

76

20

.5

50.5

18°

30

57

12

7

82.5

25

12

.5

5757

10

0

16

15

1

63.50

74

THE SHOULDERS

A

The shoulder section was a complete rebuild, causing the profile of the shoulder to change slightly. The original 'plug' was constructed mainly of wood, filler and foam, and a GRP mould then cast from this plug. The upper and lower belts are moulded into the new-style shoulder section, making it chunkier and creating a resemblance to the 80s 'Imperial' Dalek props.

Of the considerable amount time taken on the measurements included in these plans, the majority was spent on the shoulder section, owing to its complexity. As elsewhere in this document, average measurements are indicated here, where individual observations were found to vary.

This cut-through section shows you the positions and depth of the inner recess that runs around the shoulders

This Offset is Constant All Around Lower Skirt

A

10

2

35

0

152

95

25

C761

14

0

571.50

57

139

19

15

3

Gun box coverhole positionsØ5 x 4 places

Plan view on gun box

57

90

57

Section View A-AThe side of each gun box has an angled recess cut into it. From our reference information there were slight differences in the positions, so an average has been used where appropriate.

57

42

169

5

Approximately 10mm

13mm Radi Approx

SCALE 1 : 5DETAIL C

Deep This End

Upon close scrutiny of the reference photographs and other sources we have used, the horizontal contours that run around the shoulder section are wavy in most places. Production of the 'plug' for the shoulder section mould would presumably have been difficult, owing to the complexity of the design. Hence, it is assumed that a lot of filler was used and blended in to suit.

1610

81

6

14

0

91

.4

16

5

32

32

32

25

6.5

11

2

761

THE SHOULDERS

Overall outside width and length dimensions relative to the top diameter centre

Outside ShoulderProfile

Outside TopSkirt Profile

Outside TopShoulder Profile

Offset distance between the outside skirt and shoulder profile

349

25

275

300

175

25

451.

6

199

300

486

This view shows the shoulder base profile, including the correct overhang relative to the top skirt profile. The radii dimensions were hard to determine from our references, so when modelled on a CAD system, the correct offset measured between the shoulders and skirt was used to produce an arc which then indicated the profile

336

68

0

34

0

110

15.6

132

GUN BOX COVER

The gun box covers, which surround the ball joints on the gun & plunger arm, are another new addition.

This part was probably made up of 2 layers of 3mm thick MDF, glued together. A mould was then taken of the finished article so it could be reproduced in resin.

Measurements of the detail of the design were again found to be inconsistent, so once again, an average has been taken.

Typ

Diameter of top section

A

R12 Typ

R3 Typ

DETAIL A SCALE 1 : 1

R4

29

16

141

6

29

2

14

R66

R

R2

1.5 Radi ApproxAround This Edge



3mm Thick Material

3mm Thick Material

Typ

88

69

138

13

8

69

57

4R T

yp

Ty

p5

7

5.5

Typ

Isometric view ofthe completed GunBox Cover

76.20

SHOULDERS SLATS

Due to the inconsistency of the inner recess of the shoulder section, the slats on MT1 were made in two sections, with the angled piece (Section 2) positioned on the final fitting prior to painting.

The recess on the front slat is shallower due to the curvature of the shoulder section

Dimensions marked with an ® are for reference only, it is up to the builder to decide what they think is the best final positioning of the slats on his prop.

Sec

tio

n 1

Sec

tio

n 2

Sec

tio

n 1

Sec

tio

n 2

SECTION A-A

8

The thin slats used on the classic design from 'The Chase' (and the 2nd movie) onwards have now been replaced with a much chunkier version. Moulds were produced and the finished parts were cast in resin.

Curvature to followshoulder profile

1 Required

38

152.40

12

7

16 120.60

31.75 31.75

19

19

89

A

A

®

®1

2.7

32

16

38

57

6.5 12

.70

4 Required

31.75

63.50

12

7

19

38

19

31.5016

89

B

B

®

®

The Dashed line represents the split betweenthe two part that make up the finished slat

12

.73

81

2.7

57

6.5

0

SECTION B-B

Typ

13

Ty

p1

6

4.50

1

SHOULDERS SLATS

®

13 Required

The Slats are held into position by coach bolts. Each slat is counterbored slightly for the head of the bolt. The hole positions for the slats are drilled through the shoulder section and held together on the inside by the correct size nut.

Where the gun box meets the inner recess of the shoulders, you will find it necessary to modify the two long slats that fit on that area; the angled section should be cut out further, to allow it to fit flush with the surface.

Rough dimensions are given here, but final fitting will show you how much you will need to remove.

12

.71

08

57

SECTION C-C

Ty

p1

6

4.50 Typ

13

31.50

63.50

31.75

22

8.5

0

19

0.5

03

8

19

16

19

C

C

®

Sec

tio

n 1

Sec

tio

n 2

12

.7

16

38

12

73

81

2.7

32

32

45°

8.50

33

43

25.4

0

EXTERMINATOR GUN

8 Holes Ø5.0 EqualSpaced on A 360° PCD

The gun is made from machined aluminium components. This is a big upgrade from the old 'whisk' style gun of the classic Daleks. The front and rear bosses have 45° holes machined in place to house the 8 rods. Each boss is held on the shaft by a grub screw. We advise that you glue the rods in place to give the gun more stability.

Ø100 Sphere

234

315

68

6

25

.40

30

9

45

3

5

8

5

5

5.5

Front BossTap hole to suit M5 grub screw

8.50

45°

222 REF

63

.50

61

.50

45

10

14.5010

45

9

43

.40

150°

1.50

5

5

EXTERMINATOR GUN

8 Holes Ø5.0 EqualSpaced on A 360° PCD

Rear Boss

The Rear face will require machining to to suit the curvature of the ball joint

43

25.4

0

61

.5

Gun Rods 8 Required

The gun rods were made from Ø5 aluminium bar bent at 45° either end to suit the gun bosses

266

135°

22

5

THE PLUNGER ARM

The Plunger arm is made up from three sections of aluminium tube. This is the same arrangement as was used on the 1960s Dalek props; in the 1970s, only two tube sections were used.

From some reference photos we have seen, it is clear that wooden ball joints were used on certain props (As the grain is clearly visible), it is also understood that resin casts have been used as well.

Ø38.1 (1 1/2") Outside Diameter TubeWith 3.18 (1/8") Wall Thickness

Ø31.8 (1 1/4") Outside Diameter TubeWith 3.18 (1/8") Wall Thickness

Ø25.4 (1") Outside Diameter Tube

Ø100 Sphere

39

4 A

pp

rox

ISOMETRIC VIEW SCALE 1:2

SECTION VIEW OF PLUNGERSCALE 1 : 2

70

12

0.7

0

10

8

4

56.50

45

25

.4

103

39

.7

31

.8

65

3

22

27

VHH - 400

VHH - 425

VHH - 450

VHE - 475 orVHD - 475

KW-12

VX - 40

VX - 200

OD70 x 50IDx 4mm THK

VT - 32

4 OFF

2 OFF

Where classic-series Dalek props used a sink plunger, the plunger used on MT1 was constructed using components from EMA, a company which supplies ABS plastic parts to the model-making industry. Further props were fitted with plungers produced using a 3D-printing process. Either way, the finished part would need filling and sanding to give an acceptable finish.

Above we show a breakdown of the EMA components used and how the parts are assembled. Further work will still be required once all the parts are fitted together, with minor filling and sanding to achieve a good finish prior to painting.

THE PLUNGER

Some Dalek builders have produced great-looking plungers without using EMA components (which can be expensive). If you are working to a budget, please see page 16 for the outer dimensions of the plunger; there are plenty of cheaper alternative parts you can use.

INNER VHH - 400 SECTION

3213

35

45

44

OUTER VHH - 450 SECTION

16

25.40

63

6.7 REF

Ø560 OD - Ø460 ID

Ø580 OD - Ø480 ID

Ø600 OD - Ø500 ID

Neck Ring Blocks

Scale 1:5

24 Required

Vertical Strut 8 Required, 12mm x 20mm x 240Lg

Outer Neck Bin Cage

Dome Outline Profile

The neck bin for this new style of Dalek has also seen a upgrade to the classic style. The neck rings now have a flat area around the outer edge and the diameter of the rings are slightly larger. Also, the old "cloverleaf" struts have been replaced with rectangular ones.

The inner mesh for the NSD is made up of two layers; a standard fine mesh is used, as on classic-era Daleks, but this is now augmented by an outer rubber matting layer. The matting used on MT1 is called "Heronrib", which is usually used as nonslip flooring around swimming pools. As Heronrib matting is now in short supply, later builds have used a slightly different matting.

86

18

RE

F2

38

REF

81

4452

50

THE DOME & NECK BIN

Scale 1:5

The inner neck cage is usually constructed from MDF; the top cut-out details have not been dimensioned and are left for the builder to decide. The bottom cut-out should follow whatever internal diameter you have chosen for the top of the shoulder section.

Inner Neck Bin Support Cage

18

83°

420

28

0

1850

18

470

12

20

21

5

12.6

View of a Completed Neck Ring Scale 1:10

THE NECK BIN

Strut

Neck Ring Section Scale 1:1.5

The 24 blocks used on the neck bin give the Dalek neck a more robust look. These blockshave been constructed from wood and resin(depending on which prop you look at) and painted with the rest of the neck bin.

Typical size of cut-out

slight Angle To Suit Neck Bin Strut Scale 1:1

45°

16

4

2mm Radi allRound (Typ)

Ø16 Dome

32

41

20

10

.50

12

Profile machined on outer edgeof each neck ring

Each neck ring has 8 equally-spaced slots cut to suit the vertical struts. Once fitted, these are then screwed from the inside, through the neck strut, into the neck ring.

Scale 1:1

51

3 R

EF 45°

45°

11.5

45°

11.5

72

90

35

455

7.50

45

116

520

20°

31

S

130

26

0

38

13

0

THE DOME

The Dome used for the NSD was based on the 1980s Imperial Daleks and not the classic-era Shawcraft props. New features include vertical and horizontal grooves, and some shallow recesses to the front and rear of the dome.

5550

R6

60

The grooves and shallow recesses in the dome were created by fixing plastic strips to the inside of the master dome plug. These were then mirrored on to the finished GRP mould during the moulding process.

This represents the plan view of the shallow recesses in the front and rear of the dome; these are the dimensions on the surface of the dome.

76

16

458

134

R28

0

85

20

4

13

DETAIL S SCALE 1 : 1

R2

56

THE DOME LIGHTS

6

The bulb holders used are a BA15D/SMC style with a bayonet fitting. The "ping-pong" style bulbs are rated at 12V/24W.

Complete Assembly Scale 1:1.5

SECTION M-M SCALE 1 : 2

8

72

13

The new style dome lights used a polycarbonate lens produced by a company called Moflash. The outer frame is a new design and was not used on the classic Daleks. The frame assembly was manufactured from machined aluminium components comprising two rings (top & bottom) and four struts.

62

50

52

84

M

M

6mm ThickMaterial

10

31

23

14

15

6

75

13

84°

Over Curve241

808

9.50

41

3025

12

6.5

64

102

75

180

9.50

15

3

16

2

16

6

10R

10R R8

30

38

68

85

A

A

THE DOME COWL

The Cowl is a unique feature of the NSD, having never been seen on any other variation of Dalek throughout the years. The cowl is constructed from fibreglass and custom fitted to the surface profile on the dome. It is designed to shroud the base of the eye stalk and pivot. The small rectangular recess on the front of the Cowl is for an "ID tag", painted on to give each Dalek its own unique identification.

The cowl is usually not a perfect fit on the dome surface -- there are usually a few small noticeable gaps present. The inside surface of the cowl should be painted matt black, as should that portion of the dome covered by the cowl.

To Follow ProfileOf Dome

16

6

68

4

74

SECTION A-A

Cut Out70

2.50

100.

16

A

A

THE EYE ASSEMBLY

VHH - 400

VT - 400

VT - 375

VC - 90

CLEAR LENS

M3 x 8 CAP HEAD SCREW

MRH - 160P

The eyestalk, like the plunger, is mainly constructed from EMA components. Again we have included part numbers for reference. However, please double-check these numbers before you order, in case any numbers have changed. Also, we have indicated the dimensions for any builders wanting to use other components.

12 Required

SECTION A-A

100

95

.3

76

.2

69

.8

63

.5

57

.1

50

.8

44

.5

R50.0

8

40

10

25

15 25

38

.1

The eye pivot is a lot chunkier this time around, and has grooves running laterally around its diameter. We have seen a couple of versions of the pivot; one has a ribbed rubber section wrapped around it, and the other has the grooves cut into its surface. This is left as another choice for the builder. The eye discs are now curved. The parts are also from EMA and were probably just machined down to the desired sizes.

The components of the eye stalk are assembled on a piece of Ø22 copper tube (as used in the plumbing industry). This is placed in between the eyeball and stalk pivot, and each component slid into place on the tube. The whole assembly is then compressed together, probably by a length of threaded tubing with a nut on either end.

VT - 32

HD - 300 (2 -Required)

HD - 350 (2 - Required)

HD - 400 (2 Required)

30 16 16 25 16 168

9140

25

.40

75

10

1

THE EYE STALK PARTS

36

10

0 A

pp

rox

TYP

SCALE 2 : 1DETAIL R

TYP

1.50

1

6.32

R

Isometric Breakdown of Eyestalk

Ø22 Copper Tube

Thread Rod

PLEASE NOTE:

This Guide has been produced for anyone who wants to build a full-size replica Dalek prop for their own personal use. It is expressly not the intention of the Dalek

Builders Guild to encourage the unlicenced commercial manufacture and sale of full-size Daleks or Dalek related parts.

If you have any comments, queries or suggestions regarding this document, please do post your feedback on the Dalek Builders Guild forum.

The Daleks device mark is © BBC/Terry Nation 1963. Doctor Who is a trademark of the BBC. At the time of writing, the license for the construction and sale of full-size replica Daleks is held by

This Planet Earth Ltd, Crewe, Cheshire.

A special thank you goes out to Steve Fletcher for producing these plans and making them available to members of the Dalek Builders Guild. Further

technical information was supplied by Stuart Currie and Doug Inman.

Text written by Steve Fletcher, Stuart Currie and David James.

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