Introduction: Cardboard Dalek
Back in 2009 I saw a Gold Dalek Cosplayer at fan Expo in Toronto and was interested in building one myself.
I did not have access to wood or wood cutting tools but I did have access to 40x40 sheets of corrugated cardboard and I had a box cutter.
So I became a member of the Dalek Builder's group and downloaded the plans for free.
http://www.projectdalek.co.uk/mainsite/index.php/forum
I did not take a lot of pics as this was my first official cosplay/prop build and did not think about taking pics but I did manage a few of the cardboard construction....no paint or misc pics... :(
Step 1: Cardboard
So I had am almost unlimited supply of 40x40 or 50x50" sheets.
The plans I downloaded showed the measurements of a Shawcraft Mark III Dalek that I loved from the TV episode 'Genesis of the Daleks"
Step 2: Starting Cutting and Gluing
So I followed the plans and began cutting.
I used liquid nails (No More Nails) as the final glue and used masking tape as the grip to temporarily hold that cardboard pieces together.
For the Shoulder I sliced in between the grain to make an easier curve as can be seen in the pic.
I also double the cardboard walls and fender to create a stronger build.
Step 3: More Details
You can see from the pics the inner support cardboard beams and the amount of glue I used. You can also see the slits to make the cardboard bend and curve easier.
Step 4: More Detailing
The base and shoulders were all cardboard and built to specs from the plans.
For the hemispheres I had purchased 4" Christmas Balls that came in halves from Michaels. Then I had used a laser balancer to measure out the positions of the hemis....
Step 5: Painting and Weapons...
I primed the finished body with a gray primer Krylon Spray paint (about 3 cans) and then used a gloss Gray (about 4 cans).
The hemi's I primed black then sprayed a gloss black before attaching.
The neck I used a meshed table cloth to see through.
The plunger was attached to a PVC pipe from the dollar store, the death ray was a wooden dowel with cardboard
sheets painted silver
Both plunger and gun were attached to half a 4 inch hemi ball and strapped in with rubber bands.
The eye stalk was built from a tomato plastic holder from the dollar store and the attached to a wooded dowel.
The dome was created from fiberglass following the builder plans. The dome was placed on a last susan with an internal handle for me to move.
The eyes were from a landrover and the led lights were from an automotive led accessory with a trigger button.
The sound system used a car speaker and the voice mod was purchased in the UK to give that wicked Dalek voice.
I had also a motorized cooler that I drove from within that ran off two12 volt batteries... which gave me about 2-3 hours of run time before recharging
Step 6: Finished!
I was able to finish and run this little Dalek in 2012 to 2014 - Dalek Simon was able to attend 12 conventions over the course of 2 years.
During that time I split the skid so I could fit it in a Sentra...before I had rented a van which was getting costly...so since it was cardboard I sliced the skirt and saved me some money...
There is a lot more details I did not cover...but if you have any questions please ask away!
21 Comments
Question 1 year ago
Maybe a silly question but how did you attach the files to the cardboard? I've gotten this far with my own randomness 😆 but not sure how to attach the domes solidly.
Reply 1 year ago
For the small domes - I had cut cardboard circles for each small dome and used them as backers. I also had used wooden dowel pegs and measured the positions on each panel and glued them to each panel for each dome. Then I drilled a small hole in each dome backer circle. Then I used "no more nail" glue and glued the backers to the dome and then glued the dome with backers to the panels aligning each peg hole to the dowel. Hope this helps.
2 years ago
Planning on building something similar, but slimmer so it can fit thru doors XD
Reply 2 years ago
I'm also planning on using wood for the frame, since I want it to actually be usable instead of a prop.
3 years ago
how much was the total cost?
Reply 3 years ago
Hello, cost came out to about $800 CAN. Expensive parts were voice mods, original lights, balls, dome, paint, and the 3 wheeled motorized cooler... cardboard body free.
Reply 2 years ago
Who just has that much cardboard on them? Nevermind, just checked my garage
Question 2 years ago
The project dalek site is down. T.T
Question 3 years ago
How much cardboard did you use?
Reply 3 years ago
Hello,
I used about ten 40"x40" pallet sheets of cardboard
Question 3 years ago on Step 1
Hi there. I am an absolute novice at this, but I do want to give it a go for my youngest son, who is a Dr. Who fanatic. Would it be possible that you could let me know the actual dimensions for the skirt and skirt panels in inches, please.
Reply 3 years ago
Hello Wayne - you can get the plans for free with all the dimensions that I used at https://www.projectdalek.com/
6 years ago
or in a trailer!
6 years ago
and for transporting it, why dont you strap it to the top of your car, that is if it does not rain
6 years ago
Whovians rejoice, can you do an enterable tardis next, obviously it will not be the same size canonically on the inside, we are not time lords, and human tech is not that cool yet
6 years ago
please excuse my bad dalek jokes
6 years ago
EXPLAIN!!!, where do you get so much cardboard?
6 years ago
I know what I'm about to say is kind of stupid, but this is so good i would EXTERMINATE!!! for it.
6 years ago
Thanks he was a big hit at the conventions!
6 years ago
Really cute! He must have been very popular.