Mark V Sonic Screwdriver

I was recently commissioned to create a sonic screwdriver fusing a dragon them with the 11th doctor's sonic.

Some of the crazy things I did with it:

It contains the same sound/lights and tvbgone circuit as my previous models
(https://www.instructables.com/id/Working-Sonic-Scre...

The marble at the front of the sonic snaps out when you pull the trigger as it is spring loaded

The device uses 2 AA batteries that are easily replaceable by unscrewing the bottom.

I sculpted and cast an eye into the handle and claws around the marble.

And I created a set of instructions to be shipped with the device when I sent it out following the same theme
More on the set of instructions: https://www.instructables.com/id/Cosplay-Prop-Instr...

I hope you can access the video I included. If not I can upload it to youtube.

(I got two commissions at the same time and am wrapping up the second one {last image}. More detailed instructions will be included with that one, which changes colors)

Step 1: Design

When I got the project I drew it up quickly in a 3d modeling program to figure out how to make a working trigger. The final design evolved from these original sketches along the way as I worked with my client.

Step 2: The Battery Compartment

The battery compartment of this sonic consists of a piece of 4" black pipe with an aluminum sleeve around it, a brass flare nut with a battery contact soldered in (see sonic 3.0), and a piece of plastic derlin at the top with a second battery contact to isolate the positive connection. This type of battery compartment is quick and easy to build and better instructions will be included with the next sonic I post.

Step 3: The Front End

The front end of this sonic is a piece of brass tube with a floral bead epoxied on that slides through a custom cut piece of aluminum. The aluminum was cut on a lathe. Behind the marble sits a white led and an IR led to light up and turn tvs on and off.

Step 4: The Eye

I modeled an eye in clay on the handle of this sonic after a dragon's eye. I then cast it in plastic resin, put it in place with epoxy and painted it.

Step 5: The Claws

The claws were an interesting process. I first sculpted one in clay on the side of the sonic, removed it, molded it and cast it 4 times in plastic resin. After that was done I placed the four claws around the handle with a bit of glue, made the front half of the claws and then sculpted more clay around the claws in place.

Once I was happy with the sculpture I molded it in place, sealed up all of the moving bits of the sonic and cast the final piece in place. It was a relatively stressful process to prevent the liquid plastic from seeping into the trigger mechanism (which happened and led to an hour and a half of cleaning it out). The claws were then cleaned and painted with a moss style texture.

Step 6: Final Product

What I do not have pictures of:

The trigger guard. It is a piece of 1/8th inch brass rod bend and soldered into its shape then epoxied in place

The electronics were very similar to my 3.0 version

I added an O-ring between the brass fitting and the aluminum sleeve at the bottom to give a smoother closing fit.

I painted the entire sonic with acrylic paints, covered the moving parts and gave it a good clear-coat

I wrapped the center section in electrical tape and thread to give a nice textured feel.

I hope you enjoyed the images of this build. I will do a better set of instructions with my next build.

(and once I get a commission to, build something other than a sonic screwdriver. I have some fun props for my next show designed including a sword that imitates decapitation.)