Chuck TV Intersect Cube DIY working model

Chuck TV Intersect Cube DIY working model
Background: In the TV show “Chuck” (NBC Monday 8 PM EST) the hero, Chuck down loads all the governments’ top secrets as a series of encoded images from the Intersect computer.  

In season 2 (2009) we got to see the Intersect - a white translucent cube spinning inside a long vertical cylinder, its called the "Intersect Cube. "

Motivation: As a fan of the show I wanted my own working Intersect Cube - but for a lot less money than the official TV show version. 

Design Approach: Based on the images from the TV show - a white cube spins inside a long plastic cylinder with two nicely machined aluminum caps top and bottom.  Cube and cylinder assembly sits on a round metal base with four blue lights shining on the cube as it spins.  

It probably cost the show producers several hundreds if not thousands of dollars to make and required a good machine shop.  For my replicate I down sized to 9 inches diameter by 12 inches tall (probably about 2/3 the size of the one used on the TV show) and simplified the design so it can be produced for less than $100 using commonly available materials & tools.
 
The simplified model uses a craft store $5 glass cylinder “flower vase,” a paraffin wax cube, small 6 VDC gear motor, and 4 blue LEDs.
 
Build Options: This Instructable shows how to build the basic hardware and 2 versions of the Intersect controller. 

[1] The "Simple Controller" includes an on/off switch and speed control knob.  It requires just a little bit of soldering.  The total material cost when built this way is probably < $70.

[2] The "Full Function Controller" features a PICAXE 08M micro ($4) talking to your PC,  touch to activate sensor, and programmable speed  control.  It requires construction of a more complex electronic circuit.  Using a Visual Basic  App running on your PC, it can more or less simulate the entire "Intersect uploading sequence" as seen in Chuck TV episode Chuck vs the Ring.  This includes uploading and playing an Intersect image video on your PC screen ... see if you "flash" afterwards. 

http://www.youtube.com/watch?v=pRGJXG5yQCA
 
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Step 1Do Yourself a favor

Do Yourself a favor
Construction Overview - You will find it VERY HELPFUL to review the attached PDF file of construction overview diagrams before beginning this project. 

I apologize in advance for mixing inch and millimeter (mm) units ... I just find it easier to use mm when resolution better than 1/8 inch is required.
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23 comments
Jan 10, 2012. 8:40 AMpropfreaks says:
Wonderful tutorial and DIY! I will definitely be posting about this on my Prop Freaks site and Facebook. Thank you!
- @propfreaks
Jun 1, 2011. 9:20 AMtinker234 says:
wow wish i could upscale
Feb 5, 2011. 2:49 PMreskill says:
EHEEM i want just the program and not the cube so it that possible .... i downloaded the program but it is just saying TIMEOUT .. i think its becouse i have no cube.... can i fix that????????????????????>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>> :S
Mar 30, 2010. 8:13 PMnexnox says:
 Oh yeah, I programmed 2 Basic Stamps for this. One controlled the pulsing of the cube via PWM, and the other controlled the "lightning" traces in the base.
Feb 3, 2010. 8:36 PMHowardC says:
I don't mean to insult your work at all as it's quite impressive, but apparently you either don't have a hi-def tv or didn't pay close attention during the episode.  The intersect cube is a translucent blue rubik's cube knock-off.  You can buy them off the shelf, as did the prop masters.

Also you are gravely mis-informed about the budget of chuck's prop master.  Judging by some of the things on the show, until recently his budget per episode was probably around 100 bucks.  They often use off the shelf items for props that are so obscure only a total nerd would recognize them.  I think it might be an inside joke of some sort.

So just look on the net for the rubik's cube knock-off in question and you'll have an authentic replica!
Mar 30, 2010. 8:11 PMnexnox says:
 It amuses me that you are so sure of yourself and yet so wrong. I assure you that the intersect device here in question is 100% fabricated, well aside from the LEDs, Screws and other obvious hardware.
e024576 is quite right about the cube, each panel is cut out of a milk plex (gavarelli 2447 if I remember correctly) and the grid is a V angle cut that was put in by a router. The cube also had a small cluster ball of LEDs hand wired and surrounded by cotton batting and other diffusion materials.

if not obvious by now, I worked on the project. ;-)
Feb 10, 2010. 1:38 PMEv says:
How about starting with a larger piece of material it can be an "easy" drilling? Then cut to the shape you need. So you'd drill into the middle of a bigger cube, then cut off the corners of the cube so the hole will be at the smaller cube's corners.
Feb 4, 2010. 3:46 AMJohnJY says:
 That was an "authentic" replica, and this is Instructables, we don't buy our crap! We make it!
Feb 6, 2010. 6:57 PMnoahlankford says:
true, this is instructables, and we are makers, not buyers.
Feb 9, 2010. 9:31 AMlutziepv08 says:
well put. =)
Feb 4, 2010. 12:26 PMHowardC says:
He would still have to make the container.  And if you are making things that take more time, effort and money than buying the original, then you are just wasting your time, no offense.

I'm trying to improve the prop here.  The case is fantastic, but the cube just doesn't look right and that can be easily fixed.
Feb 4, 2010. 4:26 PMJohnJY says:
 True, but if someone says, "Wow dude, thats sweet, what's the cube?" 
Your answers could be 
* "Dude, I made that." 
* Or, "Rubik's Cube." 
Building your own stuff is just so much fun too. But you are right that it does take more time and money.  Lets be real though, what else could you do with your time. Sit and be bored. 
Feb 7, 2010. 2:46 PMGoodhart says:
And it isn't only the fun involved, one learns a LOT more from making then from buying, so the extra cost is towards one's education :-) 
 
Feb 8, 2010. 9:03 AMpkingair says:
Awesome job...A cube out of aerogel would be awesome...with it's almost smokey edges it would light up way too cool.
http://en.wikipedia.org/wiki/Aerogel
Feb 7, 2010. 7:00 PMgaravin says:
Nice!  Now if only someone would write an instructable for producing my very own Agent Walker...
Feb 8, 2010. 12:38 AMTurtleholmes says:
Haven't your parents covered that yet?
Feb 7, 2010. 11:05 AModdree says:
Nice job.  Next, can you show me how to make one of those ring shaped cell phones that Fulcrum agents carry?  :-D
Feb 7, 2010. 8:47 AMlordironwulf says:
I can't seem to find the translucent knockoff cube online.  Anyone have a link?
Feb 7, 2010. 8:11 AMSinnott says:
Very cool!  Just finished season two last night and then this was featured in the weekly Instructables e-mail.  I'll have to try this out when I have time.
Feb 4, 2010. 2:09 AMGreg Madison says:
 OMG !!! This is an amazing instructable. Bravo, j'adore ^^ 5*

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