Paper To Plastic Enterprise 1/350th Part II

[CJTK1701]

Welcome. I'm rehashing this project in an attempt to show what I've learned over the last year and to show that you can make your own plastic, or fiberglass kits out of blueprints and, or paper models. Beside covering the process that I've developed I'm going to cover every aspect I can on vacuum forming your own parts, working with Bondo and Fiberglass and using resins and how to create your own composite creations.

I fully intend to keep this thread on track and hope everyone else will as well.

I'm also going to be adding a series of videos showing exactly how to do these things, complete with naratives.

I hope this comes as some interest to card modelers and styrene modelers as well.

My motto is simple... "Don't talk about it, do it. Don't buy it, build it."

Keep on Trekkin!

For now I'm going to go back and do a review of the previous thread and review the process from the begining..

Review from the beginning of the previous thread.

Greetings all. I have been lurking here for some time, but was recently asked to sign up by Mr. Caudillo.

I recently built a 1/350th Starship Enterprise from paper, based on Ron's model and the Alan Sinclair blueprints.

I'm changing domians and don't have any pictures for you at the moment, but I will have very soon.

This model is 32.5" long and is in scale with the Polar Lights Refit.

I used expanding foam to fill the nacelles and engineering section, to stiffen them and provide for support.

But that's only where things begin. After I got the first parts completed I covered each part with fiberglass, after a couple of coats of glass, I sanded everything down and primered all of the parts. I then used those parts to make molds. These molds were used to create casting masters for vacuum forming. I have sent the masters off and will be using the vacuum formed parts and some resin cast parts to make a kit.

I'm not here to hype my kit, I just wanted to tell you how I used your favorite medium to make a scale model out of styrene.

When I get my site back up, I'll post some pics.

I'd really like to know how to use the software to make these models as this little exercise has got my mind whorling with ideas. Any advice, tips, or tricks are welcome.

I'm hooked on paper!

You want pictures? You got em.

Here's the Engineering section and the nacelles, as you can see they are Ron's paper model resized.

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Here is the nacelle that I enlarged.
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The Engineering section.
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Here's the layout of the saucer section.
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These are the basic supplies I've used.
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A pylon set up.
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The BC deck.
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The lower half of the saucer section.
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The first fiberglass parts.
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Some of the physical parts line out with the blueprints.
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There's plenty more to show, as soon as I get my website back up.

Thank you. I sincerely appreciate that and I will make sure to post links. I just don't want to get into any trouble and frankly I've already got feedback from the first setup on this. It's going to be a great kit.

There will be a complete set of decals included in the kit, windows masks and the directions will be full sized colored photos, on CD and posted on the website. After this ship has run it's course, the decals will be a free upload for everyone.

I'm offering a lot of freebies on the CD and I'm offering a warranty.

I think that's part of the reason I've gotten the bad press. I'm not going through the established powers that be and I'm doing everything myself.

I can't wait to show you guys the kit. I'm also offering a free electronics circuit. You'll have to build it your self, but it will be there.

I've got plans for a lot of kits and this kit will be the starting point for several variations. I'm also working behind the scenes with some very good paople and hope to have 4-6 kits out in the next 4-6 months.

I'll be doing Mecha, LIS, ST and SW subjects and many more.


Quote:
Originally Posted by Prowler901
Ah. Understood. Well, I'd like to see this succeed. We need a TOS version to go with the refit. Keep us posted.

Regards,
Todd
Will do. Below are a couple of pictures of the build-up process and some size relational examples. Comparison shots, if you will of existing kits.

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Here is the basic casting process. I used the cheapest elements possible, in this project, to show that anyone can do this and you don't need a lot of expensive equipment to create a kit.

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http://img294.imageshack.us/my.php?i...clair12ut5.jpg

It's all a little messy, but that's the nature of sculpting and molding.

BTW, this is my first kit. I've never done this before and virtually taught myself how to do it, while I was working on it.

I had originally envisioned this model as an aluminun machined Enterprise, but I spent months messing around with Mom and Pop machine shops. What you see is the result of my frustration. I got sick of getting nowhere and decided to take this route. I had the first ship components completely done in two weeks, but after that I ran into some unforseen delays. It's only taken me two months to go from concept to completion on this. I can't wait to get the prototype model done and show those who are interested.

I'll get some more pictures up today. I've started working on a build up using the fiberglass version. I've actually put two ships together in that time period, but I'm not ready to show the other one just yet.

That's why I figured 4-6 ships in as many months, because, in reality, if I start them at the same time I can come close to finishing them at the same time. I'm thinking that as I get my process down, I can probably speed everything up.

Here are the pictures I promised. This is of the fiberglass build up and is just the Engineering section, it needs some clean up but, it's a start.

http://img205.imageshack.us/img205/1...wkit39gxm4.jpg

http://img88.imageshack.us/img88/7305/anewkit39fnm9.jpg

http://img85.imageshack.us/img85/9761/anewkit39exn2.jpg

Below are the first set of decals and an example window mask.

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OK, I'm going to leave it at that for now. the original thread is here Paper to Plastic Star Trek Enterprise.

There's a great deal of review for me to do, to bring this entire project into some type of cohesive order. I want to bring everything up to date then go over some of the separate processes.

As always, any constructive feedback is welcome.

[CJTK1701]

OK, here are some of the more recent updates, pretty much in order of construction.

This was to be a section of the directions, where I was attempting to show that even if you made a mistake, you could still build the kit. There was much made about the difficulty of building vacuum formed kits and I wanted to alay some of the fears of those concerned.



http://i45.photobucket.com/albums/f6...mu/atk23-1.jpg

http://i45.photobucket.com/albums/f63/6242amu/atk24.jpg

I essentially went through and showed that anyone could build a vacuum kit and gave step by step intructions.



atk33.jpg - Image - Photobucket - Video and Image Hosting

http://i45.photobucket.com/albums/f63/6242amu/atk40.jpg



http://i45.photobucket.com/albums/f63/6242amu/atk44.jpg

http://i45.photobucket.com/albums/f63/6242amu/atk45.jpg

As you can see below things progressed and the build-up starting looking a bit more like an Enterprise.

http://i45.photobucket.com/albums/f6...amu/atk104.jpg

I was working on several build simultaneously and was putting together a clear cast version.....



http://i45.photobucket.com/albums/f6...amu/ATK208.jpg

I also came up with a few things to dress up the stand and display.

http://i45.photobucket.com/albums/f63/6242amu/ANP.jpg

http://i45.photobucket.com/albums/f63/6242amu/_anp1.jpg



I came up with a planet base and a Delta base. I ended up painting the planet base to look like Mars, the God of WAR!

http://i45.photobucket.com/albums/f6...amu/atk108.jpg

These are laser etched parts that were made using patterns I came up with in photoshop, using screen caps and other references.

http://i45.photobucket.com/albums/f63/6242amu/_anp3.jpg

Here are the patterns. I also made patterns for the impulse deck and the nacelle details.

http://i45.photobucket.com/albums/f6...cellegrill.jpg

http://i45.photobucket.com/albums/f6...illcorrect.jpg

These are clear cast domes covered with a couple of layers of frost.

http://i45.photobucket.com/albums/f63/6242amu/_anp4.jpg

That's just a small portion of what I've developed for this kit. I also gutted a bog screen TV to be used for the display and to use the electronics from.

http://i45.photobucket.com/albums/f6...amu/ATK199.jpg

I wasn't happy with the impulse deck, so I bought some various sizes and meshes of screen for reworking the herringbone pattern.



Ron Caudillo was kind enough to work up a schematic for the shuttle bay deck, so I'll be making one of those as well. There was a deck that came from an associate, but I want mine to be a bit more accurate.



This is a shot of a Klingon D-7 that I built up using the same method. I'll cover that and the Botany Bay and the ROM BOP in other threads.

http://i45.photobucket.com/albums/f6...ngonbuild2.jpg

I just want everyone to know that all of this is doable and I'm going to try and show you step by step how to do each of these things yourself.

More to come.

[CJTK1701]

I've gotten a few more things organized, so here are some more updates.

This was the preliminary set of decals that were done between myself and Alan Sinclair who made the original prints I started with along with Ron Caudillos paper model based on those prints.

http://i45.photobucket.com/albums/f6...airdecals1.jpg

This is an early stand configuration I came up with, but have abondonded for bigger, better, faster, more...



Here's a shot of some of the elementary equipment I used to create the original masters. This shows the Bondo, Fiberglass and Fiberglass Gel, I also used paper, tape and glue in the begining stages.

http://i45.photobucket.com/albums/f63/6242amu/_1.jpg

As you can see in the pictures below, I checked every part against the blueprints. Later I modified each part using other references.

http://i45.photobucket.com/albums/f6...amu/ATK234.jpg

http://i45.photobucket.com/albums/f6...amu/ATK235.jpg

http://i45.photobucket.com/albums/f6...amu/ATK236.jpg

The set of pictures below show some of the more advanced stages of the build-up, even at this point I was going over every part and checking for accuracy. Even now I'm modifying parts.

http://i45.photobucket.com/albums/f6...amu/ATK244.jpg

http://i45.photobucket.com/albums/f6...amu/ATK245.jpg

http://i45.photobucket.com/albums/f6...amu/ATK246.jpg

http://i45.photobucket.com/albums/f6...amu/ATK247.jpg

http://i45.photobucket.com/albums/f6...amu/ATK249.jpg

The nacelle dome.

http://i45.photobucket.com/albums/f6...Domenoglow.jpg

http://i45.photobucket.com/albums/f6...u/Domeglow.jpg

This shows where I began adding decals and working up the finished nacelle assembly's. The Decals pictured below are from JT Graphics and were the patterns used for Master Replicas 1/350th TOS.

http://i45.photobucket.com/albums/f6...amu/ATK256.jpg

Here's the TOS Delta base, before it was finished. Again, this was made with paper tape and glue, a little foam, some fiberglass and Bondo.

http://i45.photobucket.com/albums/f6...amu/ATK258.jpg

This is where I was reworking the upper saucer section, that's a 1/2500 Enterprise sitting on top. The more I work on this the more I see how even the mass produced, professionally made kit were in error, or inaccurate.

http://i45.photobucket.com/albums/f6...amu/ATK259.jpg

Another shot of the Mars base.



Once again I went back to paper. I used paper templates, resized from Ron's model, to assist in parts placement.

http://i45.photobucket.com/albums/f6...amu/ATK262.jpg

http://i45.photobucket.com/albums/f6...amu/ATK264.jpg

Below are some of the more recent shots of the build-up process.

http://i45.photobucket.com/albums/f6...amu/ATK270.jpg

http://i45.photobucket.com/albums/f6...amu/ATK274.jpg

http://i45.photobucket.com/albums/f6...amu/ATK270.jpg



http://i45.photobucket.com/albums/f6...t-Compare2.jpg

I contacted Don Mattys and he was kind enough to resize the disks from his waddell board, so I'll be lighting the other kit I'm working on.

http://i45.photobucket.com/albums/f6...amu/ATK242.jpg

http://i45.photobucket.com/albums/f6...u/PIC00016.jpg

Besides Don's board I've been working on additional circuits and items to make the original effect more like what we see on screen. I've shared much of this info with Don and was actively working with him on recreating the effect as closely as possible.

I've got a movie to show, but I have to get it hosted.

Below is the first Clear Cast engineering section I came up with. I'm still experimenting with different materials, but am close to having a completed clear cast version.



Here's the shuttle bay deck.

http://i45.photobucket.com/albums/f63/6242amu/a-cc6.jpg

I'm still working that ship up but hope to show it soon.

I bought a boatload of electronics to include with what I already have, because I plan on really lighting this baby up!

http://i45.photobucket.com/albums/f63/6242amu/a-cc8.jpg

My goal is to as closely reassemble the irginal TOS as much as possible.

http://i45.photobucket.com/albums/f6...geling0302.jpg

I even created this spinny, for the inside of the nacelle dome.

[Fishcarver]

CJTK &c

I am with you all the way on this!!
Jim

[CJTK1701]

Originally Posted by Fishcarver

CJTK &c

I am with you all the way on this!!
Jim

Well, OK Jim. Thanks!

[Millenniumfalsehood]

That. . .is. . .unbe-frakkin'-leavable!!

I can't wait to see the finished build-up!

[CJTK1701]

Originally Posted by Millenniumfalsehood

That. . .is. . .unbe-frakkin'-leavable!!

I can't wait to see the finished build-up!

Thanks Millenniumfalsehood and thanks for quoting scripture. it does my heart good to know that there are still men of faith.

[CJTK1701]

I finally got the movies uploaded for the nacelle effect I've been working on. These movies show a five LED sequence from a ten step sequencer. I've played with the firing order several times and when I get things a little closer I'm going to tie in five more LEDs each for each dome. Finally I'll go through and try to match the on screen effect as closely as possible.

Any constructive input is welcome.

Video of Nacelle effects1 - Photobucket - Video and Image Hosting

Video of Nacelle effectsII - Photobucket - Video and Image Hosting

These will be used in conjunction with the Waddell Board from Don's Light and Magic. I'll also be including a clear cast fan with each blade darken to appropriately match the look of the blades in each dome. My hope is that I can match the on screen effect without and running gear.

[Millenniumfalsehood]

Personally, I would not have the effects so "flashy", as the fan blade will take care of that aspect. In the miniature they simply blinked on and off, and then only a few of the bulbs actually blinked. The flashiness of the engines was due to the fan blades.

It's still excellent work overall, and would make a good companion piece to the PL 1:350 Refit Enterprise.

Thanks for commenting on my sigline. Its my way of letting everyone know where I stand spiritually.

[CJTK1701]

You're a good man MF and I sincerely appreciate your input! You have no idea how much. I know that the dome crcy is random and believe me, I've watched it frame by frame. I'm really working hard to get it right. I think that that one effect makes the Enterprise. Your eyes are naturally drawn to it. So, I'm taking heed to do it right, but really...Thanks, I mean that.

Originally Posted by Millenniumfalsehood

Personally, I would not have the effects so "flashy", as the fan blade will take care of that aspect. In the miniature they simply blinked on and off, and then only a few of the bulbs actually blinked. The flashiness of the engines was due to the fan blades.

It's still excellent work overall, and would make a good companion piece to the PL 1:350 Refit Enterprise.

Thanks for commenting on my sigline. Its my way of letting everyone know where I stand spiritually.

[Millenniumfalsehood]

No problem. I know the Enterprise like the back of my hand. I agree; the dome effect can really make or break the Enterprise, which is why a lot of modelers simply paint the domes, also because they can't do the circuitry. People can't tell you what color the ship is, but they can t ell you if the domes look right or not. Not only the blink rates of the LEDs, but also the spin rate of the fan is another noticeable thing about the engines.

The Master Replicas Enterprise got the nacelle effect perfect, in my opinion. It's worth checking out if you can find a video. If you can't I'll post a link.

[CJTK1701]

Originally Posted by Millenniumfalsehood

No problem. I know the Enterprise like the back of my hand. I agree; the dome effect can really make or break the Enterprise,......

..... got the nacelle effect perfect, in my opinion. It's worth checking out if you can find a video. If you can't I'll post a link.

I beg to differ, but eacj to his own. I've seen the MR effect in a couple of movies and still feel it could use some work, but who am I....??? Just a guy doing his best. Thanks again for your positive and constructive input.

[CJTK1701]

Once again real life has hit me square in the face and I've had to put hobby stuff on hold while I deal with my duties.

I figured I'd update this thread with a link to what I started at trekbbs. Unfortunately I was not allowed to finish that thread, however the project is on track as is this Enterprise thread. I just have to get caught up with more pressing issues.

Here's the link, I'll be back on this ASAP. As you can see. I started out with paper once again.

The Trek BBS: You build it.... How to Build-up.

[CJTK1701]

Sorry for the delay on this project, but we're having some real issues here. I hope this is not inappropriate, but for those who pray, please pray for my Wife. Thanks.

I'll get back to this as soon as possible.

[CJTK1701]

Well, I finally got to a point where I could do a little work on the Big Boy Enterprise. I've got my garage half way squared away and finally got my new room done. Well......almost done. I'm getting ready to do some major rework of this ship and wanted to show it in its current condition. I may not get to do much after tomorrow..... Right now I'm playing everything by ear and taking everything one day at a time.

Anyway, here it is before another rework, hopefully the final one, then it's back onto the clear cast, lighted, version and the Klingon D-7.

I want to thank everyone for their support. I appreciate the e-mails and PM's.