Derek The Dalek
The Hackspace Dalek - AKA Derek the Dalek
We were visiting a pub in Baldock which had a Dalek in it's Beer Garden. We are now looking after it and are going to repair it. Currently most of it is languishing in Mike's garage.
What needs doing to get Derek up and running
What sort of Dalek is Derek? Is it a real, as in based on dimensions of a Dalek seen on TV/Film, Dalek? Or something someone has made that was their interpretation? Which "real" Dalek version is Derek closest to?
Check out the Project Dalek Forums and data sources and measure Derek to see so we know what is the closes design to aim for.
After a lot of measuring and modelling It looks like the Dalek is reasonably close to the dimensions of one of the early Daleks. In the Dalek building community these are known as the "Shawcraft" Mk1, Mk2 and Mk3 and also the two 1960's movie Daleks. So that makes the selection a bit easier. Additionally, as we want to put the Dalek on a wheelchair it helps with the motorisation to use the "fenders" used on the movie Daleks. The Fender was introduced to conceal larger wheels as the movie Daleks ventured off the billiard table smooth studio floors in to the rougher and bumpier outside world. For the rest of the Dalek features we are going to pick and mix features from the different models.
Motivation / Locomotion
Paul B has two wheel chair drive chains which needs modifying and installing.
- What size batteries are required?
- What type of batteries? Answer from one of the battery boxes = CXL-42
- Need 2 Batteries, both 12V to give 24V for motors.
- Something like https://www.mdsbattery.co.uk/2-x-csb-evx12400-12v-40ah-mobility-scooter-batteries.html
- Cane & Able may be able to help with some older / used batteries which would be fine for initial testing.
- Front Wheels are castors = dia 200mm by XXmm wide
- Dimensions of drive wheels = dia 320mm by ~80mm wide
- Tyre Sizes
- (57-203) 12.5" x 2.25" "Innova" Brand Grey rubber - 2 new tyres acquired
Footprint of wheelchair base
- Will it fit in the Dalek Base?
- Mounting points
- Mating the wheelchair to the Dalek
- Control of movement
- One wheelchair has the full controller still attached. Paul may have another.
- Controller is a Dynamic DK-PMA01 Shark Wheelchair Controller
- Does the controller work?
- It does. Drives the motors on the existing older wheel chair. However, as you can see from the diagram above from the manual the brake circuit on the controller is 24V, 24V motors and 24V brakes. The newer wheelchair has 24V motors and 12V brakes.
The head looks pretty good but is missing some elements and has some design issues:
- The "Hat"
- The Hat is of approximately the right dimensions and form.
- It has suffered some damage in the past. It houses:
- The head rotation mechanism
- Fairly rudimentary bolt as a pivot. Needs work
- The Head rotation "stick"
- There is a mount for this to allow the operator to turn the head but the stick itself has snapped off. Needs either mechanising or making more solidly in metal for hand operation
- The Eye stalk mechanism
- Very basic bolt pivot with a string to pull and a return spring, which is missing.
- The Antennae Lights
- Rough holes in about the right places. Very poor light setup, a pair of indicator lenses may not be the right design. Needs major reworking (See illumination below)
- Needs work to repair damage
- Construction is fibreglass for the hat and plywood for the internal structure.
- The Head body
- Well built but of the 3 rings which should go round the head the bottom one is missing.
- On of the 2 remaining 2 rings has been knocked and dislodged.
- The remaining rings are showing signs of damage.
- According to the Dalek Project guides we are missing vertical strips on the outside of the mesh but the inside of the rings. Each strip consists of 3 dowels bonded together.
- The Head body has a front panel with mesh with no backing so that the operator can see out.
- Along with the hat some work is required for the rotation mechanism to get it working smoothly.
The Mid-section is very substantial and well made but seems to be missing a lot of detail.
- Construction is plywood and fibreglass.
- The Arm ports have the correct size orifices and are chamfered on the inside to allow installation of the arm sphere joints.
- The arm ports have internal studding for a clamping mechanism for the arm spheres.
- External Structures missing
- From reading the Dalek Project build guides the mid-section is missing some detail. Exactly how much depends on which Dalek version you want to replicate.
- Decide on which version we are replicating and make the relevant structure.
- Sort out arm mechanisms / structure for pivot spheres.
- Procure suitable spheres.
The Skirt is pretty well built.
- Construction is plywood and fibreglass. The forward section of the skirt itself is fibreglass. The rear thin ply possibly with fibreglass over the top.
- The internal structure and seat is pretty solid and well constructed.
- The bottom edge of the skirt flange / base is just a single thickness of ply. Again depending on which Dalek Mark we go for this would change thickness.
- Wheel Chair installation / integration. Need a 3D model of the base and a rough model of the wheel chair structure to be able to see how the two could be mated together.
- Missing domes need addressing.
- Dome attachment isnt great and may not be as the Dalek Project guides suggest they should be mounted.
- Dalek Model Version 0.1
- Dalek Model Version 0.2
- Dalek Model Version 0.3
- Dalek Model Version 0.4
- Dalek Model Version 0.5
Weapons, limbs and stalks
Derek is missing all his suckers and stick out bits. Replacements need fashioning and installing.
- What size orifices does Derek have for installing limbs in to?
- Correctly sized to accept ~100mm (4") spheres
- Eye Stalk
- What does Derek have for an eyestalk?
- Nothing... but the pivot assembly is in place although it is rather rudimentary
- What is there what is missing?
- Have the pivot, it isn't the "official" size but it exists.
- Pivot has really poor mechanical mounting for eye stalk.
- Need stalk tube, acrylic rings, acrylic tube, Eyeball, iris/aperture, camera, LED
- The "Gun"
- Entirely missing. Need to decide on preferred Dalek version for defining correct gun design
- The "Plunger"
- Entirely missing. Need to decide on preferred Dalek version for defining correct plunger design
Externally the finish is pretty good but some of the body domes are missing and need replacements making. Ideal candidate for a vacuum former
- check over externals and compile a list of tasks
- Domes are approx 103mm dia and 45mm tall
- Correct number of domes are used
- In all missing 5 domes on the skirt
- 2 domes are not attached but we have them
- we have one dome base which has fallen off
- Filling and painting
- There are quite a few areas which are damaged and need work to repair but the paint looks to be really high quality.
- Final Finishing can be addressed once all the mechanical issues are addressed.
External lighting / illumination
- Head lights
- Type and Style appropriate for design
- Weapon Lights
- Does the weapon illuminate?
- Eye Stalk illumination
- Does it have lights?
- Other Lighting
- Are there other illumination effects
- Skirt illumination
- Head illumination
Sound effects for Dalek Voice modulation and weapon
- Dalek Voice
- Ring Modular Circuit
- Best way to achieve this?
- Make a Ring Modulator?
- Use a PI?
- Use an Arduino?
- Buy the Project Dalek Forum Mk6 System, ~£100 but does everything.
- Weapon Sounds
- some kind of Pi or Arduino Sample player?
- Remote Control
- Be able to drive the Dalek remotely?
- Eye Stalk video camera
- Set up a remote viewing video camera?
Found this site
which links to this
which in turn links to Github page
and this PCB
So I have ordered the PCB (you get 3 for $23!) Will see what develops.
- Parts List
- MCP3204 RS Stock No.: 379-2465
- MCP4921 RS Stock No.: 738-6027
- Audio Jack
- 1K resistor
- 1.5K resistor
- 330 ohm resistor
- 0.1 uF capacitor
- 10 uF electrolytic capacitor (2mm spacing)
- LED T1-3/4 (5mm) RED
- 36-pin header
- 10K Trimpot