Home > Dalek Project > Head Section Construction
Modified:22:21, 22 October 2013

The neck section was made from MDF and softwood. Although quite wastefull to keep cutting rings, all the centre pieces were used on other parts. The sizes were all guessed from photos.

Making the Head Shell
The interior of the head showing the inside of the plastic dome attached to the wooden skirt made of 2 rings and 16 angled supports worked out on 2D Design. Also in the picture is the beginning of the eyestalk supports being checked. More details on the Eyestalk page.
The head design was based on part of a plastic dome of 3mm clear acrylic and a diameter of 300mm with a wooden skirt attached to form the lower part. The shape was drawn on 2D Design to find the angles needed to match to the neck assembly.
Adding The Eye-Stalk Shroud:
The eyetalk shroud and surround were shaped and constructed from more flexible strips of wood forming the outline of the relief sections. The hood was made from 6mm MDF and cut from a card template that was shaped in position. The skin on the relief was about 1.5mm birch plywood. Being very flexible it is easily shaped. The edges were mitred and sides made good with more car filler - you can't beat Isopon P40!
Head Pivot and Comutator Rings:
To enable the head to spin continuously, the power supplied to the head had to be done via rings and brushes. The rings were made from strips of copper backed with adhesive. The strips were meant to be used to form simple circuits on wood or card, but made excellent conductors. Wires were soldered carefully to the edges of the rings so as not to interfere with the brushes on the neck. Three wooden brackets with elongated holes for adjustment support the pivot pin for the head. This meant the head could be centralised.The pivot support is made from 9mm MDF cut with three arms secured to the head surround.
The pivot pin is made from 25mm black pipe I found somewhere. This pin fits through a similar support frame in the neck section and holds the drive motors. Further information on this is on the Neck construction page.
Fitting the Tram Ring
The tram ring rests on the drive motor wheels enabling the head to rotate freely. It was decided best to drive from a tram around the edge as this gave much more mechanical advantage than by turning the pivot. The pivot now just acts as a guide. Eight miniature right-angled brackets connected the tram ring to the head. The also had elongated holes to allow adjustment if needed.
Image of tram ring in place on the neck without the head attached. The tram ring in place above the pivot support.
Fitting Light Sections:
The holes for the lights that react to the voice (I'm not sure what you call them...ears??) were cut by drilling the outline of the holes with a 3mm drill and then filing and sanding to size. Tubular objects of varying size with sandpaper helped to keep the shape round and not become oval. The item shown is... a small bottle of PVA!
The light holder assembly. A plastic clip was made to fit around the pins on the bulb case. An easy way of holding it into place. The bulbs were 5 Watt 12v car indicator bulbs. Wires were soldered on - lazy. The interior of the head with all parts in place. Details of the Eyestalk mechanism can be found on the Eyestalk & Mechanism page.
Written and Constructed by Phil Townshend 2009
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