Introduction: Motorizing the Doctor Who Pinball Dalek
Got yourself a classic 1992 Bally Doctor Who pinball? Did you know the first units coming off the assembly line had a moving Dalek robot? The bean counters axed it for cost reasons. But now you can add it back, and it's better than ever! These instructions cover how to install the Ultimate Dr Who Wobble Head Kit by DIYPinball available at from http://wobbleheadkit.com
Step 1: Get the Wobble Head Kit
You will need the Ultimate Dr Who Wobble Head Kit by diypinball(r) available at from http://wobbleheadkit.com
Step 2: Remove Dalek From Pinball Machine
Step 3: Drill Dalek Head
Using an 1/8" drill bit, drill a hole in the Dalek's head
Step 4: Pry Dalek Head Off Body
The head is glued to the body. Pry it off using only your hands. Do not pull the robot's nose. Apply pressure between the bottom lip of the robot head and the body.
Step 5: Insert Motor Bracket
Center the motor's bracket in the neck of the body. Note there are four screws that protrude a bit from the bracket that will help you center the bracket in the body. To ensure the robot head points in the correct direction - 1. Make sure that the large notch is facing forward as shown and 2. Make sure that the bracket is parallel with the flat surface on the back of the robot.
Step 6: Mark Holes
There are four outside holes, mark them for drilling.
Step 7: Drill Holes
Drill the holes you just marked in the previous step
Step 8: Screw Motor Down
There are four large flat head screws that hold the motor assembly into the head. Ensure they are totally flat and remove any extra plastic squeeze-out that may appear - as this may hang up on the rotating head mechanisms.
Step 9: Mount the Control Board
For shipping reasons, the control board isn't attached to the motor. Attach it now using two cap head screws and a 7/64” Hex Wrench.
Step 10: Connect Servo
The wobble head kit from http://wobbleheadkit.com comes with the servo already connected; however, should you accidentally disconnect it, you will want to reconnect it to the three pin connector that marked "servo". You will also want to make sure it's not reversed - so the white wire is connected to the "WHT" pin which is facing toward the big servo motor.
Step 11: Install Head Bracket.
Install the bracket within the Dalek head. Use the two supplied small flat head screws. Make sure the bracket faces the nose of the robot as shown.
Step 12: Install Dalek Head Part 1
Before installing the head to the Dalek, you'll want to put the fender washer under the bracket and the large pan head screw through it. Hold it upside down while installing in to the robot body.
Step 13: Install Dalek Head Part 2
Make sure that the square in the bracket is sitting on the rod correctly, then once the screw is started, you can flip the robot right side up and tighten the screw.