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 Reassembly

 

Silver basecoat and two-pack lacquer...

With the painting complete it was time to test fit everything. Domelights, eyestalk, gun, arm, neckmesh, base rubber and collars have all been fitted here.

Shoulder mesh and slats are still to be added as well as the hemispheres (blue ones for this 60s-style Dalek). An extra layer of neckmesh or voile also needs to be added to further obscure the neck, so the operator won't be seen.

 


 

Hemisphere former

 

Making hemispheres...

This is the mould I used to 'pressure form' PETG plastic into hemispheres. Each five-inch square of plastic was mounted in a frame and heated in the oven. Once it had begun to 'sag' it was pressed over the mould, pushing the plastic into the desired shape.

For more information on this process, please refer to the 'Dalek Builder's Workshop Manual'.