The DHD: How it was Made
Updated: Apr 8, 2019
Post by Cristofer Adrian
To visit Cristofer's 1st post, The Dial Home Device--DHD The Stargate Dial Life-sized Reproduction," click here.
HOW IT WAS MADE:It starts as it usually does with most builds - drifting in a daze through the isles at home depot hunting for new tools and lumber.
Circles are drawn with a measuring stick, pencil and a screw.
I started playing around with the levels of elevation using scrap wood.
Once my elevations and diameters were correct (I ended up having to reduce the size of the top rings!), I begin cutting spokes into the wheels. This reduced the weight tremendously.
Clamping structures together:
My second trip to the laser cutter produced my second version of the buttons.
Now it was time to start shaping the edges using a custom angle jig and bondo and day and days and days of sanding and smoothing.
Once the angle were all shaped in, I decided to use a lofting technique to fill in the tables.
Lofting the skeletal structures:
I produced the skin patterns by taping construction paper to the ribs and cutting the shapes. I then scanned the patterns and transferred the artwork digitally to vectors. The last step was laser-cutting the skins in 060 styrene.
Styrene skinning continues on the main structure:
My first look at the substructure.
Laser cutting the glyphs:
Behind the scenes I have been designing different versions of the pedal buttons and here you can see the third generation of button bases - some in 1/4" wood and some in construction paper. The paper glyphs are my third generation attempt but still need a tiny adjustment. When working in a sloped circle, things get tricky. The dark tiles are laser cut EVA foam I produced as an experiment. A very SUCCESSFUL experiment. I'll be developing a design to laser cut the tiles as a single strip I will wrap around the dome.
After a few more hours of shaping, this is the nearly completed DIAL BASE coated in automotive urethane. There's still a ways to go!
A few hours at the laser cutter with acrylic and styrene, and then another few hours glueing: (p.s. the glyphs aren't glued on yet, and they're in no particular order. I realize I may need to resize and re-draw some of them. The symbol maps I found online are not entirely accurate.
Placing the glyphs in their final positions:
I innovated last year and learned it's possible to laser cut AND raster EVA foam. That's that's how I decided to do the globe liner detail trim. Visit the KNIGHTS SHIELD to see more of this unique technique.
Here is my third generation of glyphs which were laser cut onto 1/8" acrylic.
Blending the last layer of detail. PATTERN COMPLETED!
For further information or to order this or other amazing products from Cristofer, visit http://chaucer44.squarespace.com/stargatedial. Visit us this Wednesday for Cristofer's next post, "DHD, dialing Home Device: Making the Mold!!"
If you are looking for some non-toxic alternatives to some of the materials used in this tutorial, please visit https://www.greenbuildingsupply.com/.
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