So get it on, bang a gong.
Disclaimer: I am not a true Stargate fan so details are not 100% accurate. It's papier mache, for crying out loud... But please argue the hypothetical on the potential of such a device, I'll believe you.
Dandy dialing device. The party you have dialed is not available or you are not in the service area to place a call...iphone4 users.
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Step 1: I'd Hit It...
I don't know why I keep accumulating all of this cardboard to recycle but time to put a dent in the pile so some of it doesn't end up in the landfill.
I had a few pieces of high quality thick box cardboard to use.
I also had a few spare cymbals from Caitlin's drum set that were collecting dust. I used the 16 inch crash for my prototype as I didn't know how big this was going to turn out. I guess the 18 inch crash/ride would have worked as well.
A cymbal, as big as you have
A piece of wood 1x3 stock couple of inches longer than the diameter of your cymbal
5/16th inch x 4 inch carriage bolt with washers and nuts for mounting cymbal
Krylon metallic gold paint, you could use a greyish color for the authentic Stargate look
big bottle of regular glue for papier mache
You can use regular white glue for everything but I found carpenter's glue to have a better tack and quicker set up when doing papercrafts. Hot glue from a hot glue gun also has its utility in tacking parts together that you cannot really clamp together until the glue sets up.
hot glue gun for hot gluing
scissors, utility knife, ruler, straightedge, compass and pencil
CAUTION:Sharp implements can cut you, hot glue hurts or can cause burns. Hot glue can ooze from joints to napalm your fingers or the heat will come through the part as you press on it. Allow to cool sufficiently before handling.
Heed warnings and instructions on paint cans. Apply only in well ventilated areas.
Have your more mature kid supervise you if you cannot act responsibly.
Step 2: On Target
Lay out the biggest sheet or piece of carboard you have.
If you have holes or tears in the piece, don't worry too much as we will fill them in and papier mache over it.
We will also be layering our cardboard several thicknesses so that we get a strong piece of ply-board. Each layer has it's grain or corrugation perpendicular to the previous for greatest strength.
Also, smaller pieces can be tacked on to the next creating a bigger piece. Just have the other layer overlap or cover the seam.
Place the cymbal on the cardboard.
Take a compass or dividers and set the distance to about 1/2 to 3/4 inches.
Scribe around the perimeter of the cymbal.
Take a compass or dividers and set the distance to about 3 1/2 inches.
Scribe a circle around the cymbal tracing.
Scribe a bigger circle around the circle you just made.
These circles mark off the inner and outer rings of your Stargate.
Step 3: Show Your Support
We need to create a central support column on which to mount the cymbal.
Since we didn't have a real gong which is suspended by wires from the top, we can mount the cymbal using its center hole.
You can take a length of wood that will span the hole in the middle of the Stargate. I happened to have a piece of scrap laminate flooring that will do the trick.
This strut will be embedded in layers of cardboard. The top and bottom of the support piece will be flared into the circular opening with cardboard side pieces
For the first layer, cut out a piece for the end. Dig or cut out a space for the end of the support in the cardboard. This ensures that that piece will lay flat.
Create and shape pieces that will flare the ends of the center support piece to the rest of the cardboard shape.
Layer cardboard over the center support piece and on the bottom.
Cut out the two "soundholes" in the Stargate.
Step 4: Inner Base Ring
Cut long cardboard strips 2 1/2 inches wide. The corrugation should be perpendicular to the length so it is easier to bend.
Hot glue is used to tack and glue the inner wall of the inner ring. You could also use regular glue but would have to tape in place to hold it until the glue sets.
Follow the guidelines that you laid out. Glue on another piece of cardboard if you find the strip is not long enough.
Repeat for the second concentric ring.
Make the walls for the two outer rings.
Double or triple layer the inner facing sides of the rings.
Now take some cardboard strips 2 1/2 inches wide but have the corrugation go parallel with the length of the cardboard.
Fold in an accordian zig-zag shape. While folded, smear glue on the side surfaces and the bottom. Expand and place in between the walls of the inner ring. Adjust so that the "V" channels touch and are glued to the walls. This will be our structural reinforcement for the rings.
Now take strips of cardboard and start to "shingle" our inner ring.
Cut pieces to fit the edges of the inner ring. They will radiate outward and have gaps but that is covered with a second course of shingles.
You could just cover it with one piece and tracing below to get the outline but I wanted to have a textural feel created with the overlapping pieces.
Step 5: Two Ringy Dingy...
Make the pleated cardboard reinforcement for the outer ring.
Shingle the top of that ring.
Shingle again with a different thickness of cardboard to add to the texture.
Step 6: Papier Mache...
With the inner and outer base ring double shingled, it's time to start papier mache'ing.
Use a mixture of half white glue and half water in a small bowl. A takeout container is perfect for this mess.
I decided to use paper towels to cover the inner and outer rings. The texture of the paper towels will add to the cool look of the Stargate.
Cut paper towels into small manageable strips. Soak and then lay gently over the cardboard. Don't press too hard to adhere or you will flatten out the texture. Also, soggy paper towels don't like being worked too much or they will bunch up and tear.
Step 7: Dialing Ring
Create the separate dialing ring just like the others.
Cut strips that are the height of your inner ring.
Form the inner and outer ring of the dialing ring. Double or triple layer the inner facing parts of the rings.
Make sure that they can rotate loosely in the groove.
Shingle the top of the dialing ring walls.
Take it out and then reinforce with the pleated strips.
Papier mache the top with paper towels.
Papier mache the bottom unseen edges with regular newspaper.
Step 8: Create Chevrons
For the chevrons, cut pieces of cardboard were layered and glued.
Pieces were cut and double layered for strength and thickness.
Side overhang was glued on.
Papier mache to hide all the raw edges.
Step 9: Glyphs
There are plenty of diagrams of various Stargates to be found on the interwebs.
Glyphs are the symbols from the Ancient beings that you find on the dialing ring.
After all the papier mache was dry, I coated the chevrons with a layer of carpenter's glue to give it a smooth glossy surface.
After marking the glyphs...yeah, you try to divide a circle into 39 sections, I just copied the symbols as I went around the chart with only those that fit my Stargate dimensions.
I then used a hot glue gun to trace over the glyphs. I also added textural lines and wedge shapes that detail around the ring. I suppose you could also do with a caulk gun but you would have a longer wait for it to cure.
Step 10: Prime Directive.
Prime and paint.
Step 11: Make It Glow...
Place the dialing ring in the channel.
You can squeeze and form the cardboard to get it to spin more freely.
Hot glue on the chevrons into position. Space out the 9 chevrons evenly around the perimeter.
I did not have time to mod one of my emergency bicycle flasher units to make the chevrons light up in sequence on this one.
I had some reflective tape with red and white panels.
I cut some thin strips to place on the chevrons to simulate the blinkenlights.
Step 12: Add It On, Bang a Gong...
The cymbal is actually positioned away from the central support strut about 2 inches so that it can vibrate.
Drill a 5/16th inch hole in the center of the central support strut.
Add a support block to bolster the mounting bolt.
Place a 5/16th inch bolt through the cymbal. Use large mteal washers and felt washers to allow it to vibrate. Use a nut to hold in place. Use additional nuts and washers to secure.
Adjust the bolt and spacing on the central support.
You need to make a stand or lean up against something to use vertically.
Maybe embed it in a stone base.
Tune your gong or was that tune a fish.