"Doctor Whoo oo, HEY,  Doctor Who,  Doctor Whoo oo, HEY,  The T.A.R.D.I.S". Who remembers that little gem of a song (or not as the case may be ;-) from 1988 by The Timelords (AKA The KLF). Anyway that was NOT the inspiration I got for starting this project, but photos of homemade Daleks I have seen on the net, projects people have made on Instructables, especially the ones made by craftycounterpart and by Sci_Fi_Steve which are very cool, and of course Doctor Who's 50th anniversary certainly were.

Here I will show you how I made my scratch built Dalek using items I rescued from our recycling bin, a broken but functional radio controlled tank, and other bits and peaces I had laying around crying out to be used. I hope this Instructable will give you some inspiration to make your own Dalek, as I think we need more of these poor misunderstood creatures roaming around our own little planet (even though they are hell bent on controlling the universe).

Here is a list of materials I used.

A radio controlled tank, broken but still functional
Corrugated cardboard
Sheets of scrap A4 size paper
Thin Cardboard (from a cereal box or similar)
PVC carpet underlay foam sheet, 12mm thick
A plastic lid from a gravy jar
3 flat top plastic lids from deodorant cans
1 rounded plastic lid from a shaving foam can
4 dried out thick marker pens
Some length of thin steel wire
Electrical wire
2 red LED bulbs
1 green LED bulb
2 round ended plastic tubes
1 Christmas tree ball ball decoration
A WiFi web cam
A Bluetooth speaker
Bag of small modeling tacks (tiny nails)
1 kiddy size football
7 8cm long screws
A 9 volt battery snap connector
A strip of 10 Blue battery powered LED's

Items I had to buy.

Bag of 50 polystyrene balls, 3cm diameter (about £3 / $5 inc shipping)
1 can of grey spray primer 500ml (about £4 / $6.50 i/s)
1 can of gloss black spray paint 500ml (£6 / $9.80 i/s)
1 can of gold spray paint 500ml (£6 / $9.80 i/s)

Tools and adhesives.

Phillips screwdriver
Set of small electrical use screwdrivers
Craft knife with new blades
Wire cutters
Soldering iron
Insulating/electrical tape
Aluminum tape
Duct tape
Super glue
1 tube of Grab adhesive and applicator (No more nails/ Gripfill or similar)
Black permanent marker
Pen or pencil
Very fine sanding paper

So on with the build. Lets begin with the base.

Step 1: The Base.

I feel I should mention without trying to put a downer on things, a Dalek really is not the easiest of things to make. But with a bit of research, trial and error, perseverance, and a little luck, it is worth it. The good thing is, if I did go wrong on something (which I did a couple of times) it was no real bother, as most of the materials I was using were destined for the rubbish/recycle collection anyway, and there was always something else I could end up using.

 The radio controlled tank I had collecting dust, was old and damaged, which was mostly bodywork and a missing wheel, but after replacing the rechargeable batteries and testing it functions, it burst in to life. So now I had a working chassis, forward, reverse, left and right, and a motorized  turret which turns about 270 degrees. The motorized cannon which went up and down was also broken, but the motor did still work which I was really pleased about because I had a great use for it. More on that later.

The tank chassis measured 35cm by 15cm and 5cm deep from top of chassis to the ground. To make the base, What I did first was to take apart the body from the chassis and remove the cannon motor, battery leads, and aerial wire. I then cut and extended the wires, then pushed them through a small hole I made in the top, slightly off center, of the turret. I then started to make the base.  Here's how it was done.

1.) Using a sheet of A4 paper as a template, measure and mark out the 11 sides that will help form the Dalek body shape. Using the paper template helped me a lot, as getting the right shape was a bit of trial and error. Measurements I used are as follows starting from what would be the back of the Dalek and finishing with the pointed front. It should be noted that these measurements are what I worked out using photos I found online as finding exact specifications that I could scale down, at the time, proved to be difficult, so I used my best judgment.

Back, 12cm
Back sides,  6cm
Main sides, 10cm
Off center sides, 5cm
Front sides, 8cm
Fronts, 6cm
To help make it clearer, the measurements can also be seen on the in-photo information. When the sides are marked out and your happy that both left and right sides look equal,, cut out the template.

2.) Using a peace of strong corrugated cardboard the same size or larger than an A4 paper sheet, place the paper template on to the cardboard and use a pen to draw around it. Then cut around the marked edges of the cardboard using a craft knife and ruler (or a peace of straight wood) to help keep the edges nice and straight.

3.) This part is a bit of trial and error. I needed to cut out a circle of the center of the now shaped cardboard to fit over the turret of the tank, and leave enough room for the turret to move freely with no obstruction, as the gap between the chassis and turret was not completely flat. So cut small to start then cutting more where needed to avoid cutting out to much cardboard and making it weaker. As seen in the photo, I did not cut out a circle but rather cut to shape of the protruding body parts of the tank and helping make the base level.

4.) Using some more corrugated cardboard, cut out some 2cm wide strips, cut the strips in to 4cm peaces (about 22 peaces should do), then bend them in half to make "L" shape brackets. Now glue 2 brackets to each edge of the base with the hanging part facing towards the outside of the base and as flush as possible.

5.) Now using a thinner peace of cardboard like a cereal box (or pizza box like I did), you want to cut out some strips that will cover the sides to hide the wheels and to attach some under chassis lighting if you wish. The measurements I used were 3 an a half centimeters deep leaving 1.5cm ground clearance, and enough cardboard to go all the way around the base plate made previously.

6.) Using some glue (I used super glue) apply some drops on to the outside of your "L" brackets then attach the cardboard strips. I held the strips in place using some cloths pegs until the glue set.

7.) Attach the base to the tank chassis using either glue or some screws and washers (I used glue).

8.) Finally in this stage, I had a strip of 10 battery operated blue LED's left over from an old project.(cheap to buy, around £3 / $5). Using some duct tape, simply attach the lights to the inner side of the sides of the base, making sure the battery pack is at the back of the base so you can gain easy access through an inspection panel to be build in to the body later.

On to the next stage.
cool doctor who i ♡ that show
<p>I love Doctor Who! I don't think I'd be able to make this, but it looks awesome!</p>
<p>cool dalek!! I am going to try this!</p>
<p>Dude...what an awesome Dalek! You got my vote...great instructable and love the RC element! Oh...and thanks for the shout out on my humble little Dalek ornament :)</p>
<p>Thanks for the kind words crafty. Glad you liked it. And your welcome for the shout out. It sprang to mind when I saw your Dalek ornament that you could make a drafts or chess set using the different Dalek ranks. Anyway, thanks again buddy.</p>

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