2001 ASO USSC Discovery One

Discussion in 'Science Fiction & Fantasy' started by DanBKing, May 15, 2012.

  1. DanBKing

    DanBKing Active Member

    WOW! I'm honored to be 'Stuck!' :happy:

    So, best I 'stick' with it and get 'stuck' in.....

    Thanks very much everybody! thumbsup
    Revell-Fan likes this.
  2. DanBKing

    DanBKing Active Member

    Just a quick update.....

    I managed to squeeze an hour of modelling in last night, and fitted the airlock door, that I made earlier in the thread.....
    Nothing special with the fitting, just a case of aligning everything accurately.

    I am working on the pod bay doors next, but I have a busy first half of this week, what with dart tournaments and other things requiring my presence, I probably wont get much done on Discovery until later in the week.

    Will keep you all posted as I progress.

    DSC_0083.JPG DSC_0080.JPG
  3. mcusanelli

    mcusanelli Member

    Your work on this model is absolutely incredible! Not to mention your patience :)
    DanBKing likes this.
  4. DanBKing

    DanBKing Active Member

    Thank you, Mike. :)
    I am pleased with how things are turning out so far.
  5. DanBKing

    DanBKing Active Member

    Phew! That has been a busy week or so ...... But not on Discovery, unfortunately ....:(

    Earlier in the week, I went to the hobby store and purchased the full range of plastic balls from them!
    I now have balls ranging from 4cm up to 25cm ...:)
    I need a smaller size ball to shape the pod bay doors correctly. The ball diameter used for the command sphere was 13cm.
    I used a 8cm ball for shaping the pod bay doors.

    The water shaping process for the pod bay doors was slightly different, as to how I did the main sphere. In this case I used half of a 8cm and a 7cm ball, plus a small kitchen scouring sponge. Oh, and a heavy house brick!


    Each pod bay door was carefully cut out and then dampened with a damp cloth. The dampened door was placed inside the 8cm ball and the sponge then placed on top of the door ....


    Pressure was applied to stretch the doors into shape. The 7cm half ball was then placed on top of the sponge.....


    Once I was happy with things, I then placed the heavy house brick on the balls and sponge and let it to dry over night.


    The doors came out well. And to show the benefits of water shaping, the doors are now perfectly formed, and in the pic below, the separate 'leaves' of the doors have not been glued or back-tabbed yet! Holds the shape beautifully. :)


    I then cut out the pieces I want to use for detailing the doors, from a spare copy...


    And, unfortunately, that's as far as my free time would allow me to get ....

    I am hoping to get the doors completed and fitted to the lower sphere, over the next couple of days.
    Then I have to finalize the lighting and associated electronics for the cockpit lighting and then the two half spheres can be joined permanently. :)

    I'm looking forwards to getting the command sphere finished ..... Nearly there ....:D

    See you all soon......:)
  6. Revell-Fan

    Revell-Fan Co-Administrator Administrator

    I always knew that tackling UHU's Discovery would be a very ballsy project! ;) Well, I had never doubted that you would not have the balls to do it. :D Awesome! thumbsup

    BTW, these balls might be very useful in future projects, too. Speaking of "future", do you remember the "Comet" from "Captain Future"? She is of a similar design. :)
  7. DanBKing

    DanBKing Active Member

    I was thinking more along this line ....... ;)

    Last edited: May 26, 2015
    Revell-Fan likes this.
  8. zathros

    zathros SENIOR Administrator

    The were in such a hurry after discovering the second monolith, they basically stuck an Aries on the tip, so you will find the building of this model very familiar. You have really shown how water forming can really make compound shapes. I hope more people take this technique on. So many paper models could be made to look so much better with this technique. You would not believe what it does for ship (as in boat) hulls!!
  9. DanBKing

    DanBKing Active Member

    WOOOAH! I didn't think life could get any busier or crazier than it has been the last two weeks.... PFFFF!

    I decided on Thursday that the coming weekend was going to be a relaxing one, and was gonna get some more work done on Discovery..... So, Friday morning I got out of bed before the first sparrow fart, and headed off to work 2 hours earlier than normal, with the plan that I could then leave 2 hours earlier! Well, that didn't quite work out to plan....... :(
    It was about 20 minutes before my due time to leave, when all of a sudden the whole building starting shaking........ Not an earthquake, more like the sound of a large 18-wheeler ploughing through the place...........:eek:
    As I've mentioned before, I work for a document archive company, well, in the warehouse all the pallets of boxed documents are stored in racking, 10 meters high. We use reach trucks to move the pallets. These trucks can reach a maximum of 10,2 meters, thereby placing pallets at 10 meter heights. On average, most pallets weigh in the region of 800 kilograms (just under 1800 lbs.)
    Anyway, one of the reach truck drivers was putting a pallet back at maximum height when the truck blew a hydraulic hose........
    Of course, with no hydraulic pressure left, the forks and pallet dropped like a dead weight, slamming down onto the top most cross beam of the racking.
    The resulting stresses and forces on the beam caused it to bend in the middle and rip it out of its mountings which then completely collapsed onto the next level. This vertical domino effect took out 4 levels of racking, causing 16 x 800 kg pallets to fall between 6 and 10 meters (20 - 33 ft)...........

    And the reach truck and driver was directly below it ...........

    The drivers are trained to stay in the protective cage of the truck in an emergency and that probably saved his life....
    It took 8 of us, 20 minutes or so, to dig him out from under nearly 13 metric tons of paper and smashed boxes, pallets and steel work from the racking. What made the task worse, was everything was coated with dangerously slippery hydraulic oil.....
    Thank god he was uninjured, albeit VERY shaken up and when we had gotten him out, his first words were: "I need a f*****g whiskey...":)

    Our experience was not as extreme as this in this vid, but it shows how quick something like this happens and escalates....

    Anyway, I ended up leaving work 7 1/2 hours later than I should of done.......... Definitely not a good way to start the weekend.......:(:mad:

    Anyway, back on topic..... :p

    I DID manage to find 1/2 an hour here and there to do a little on Discovery though .....

    I got all the detail work done on the pod bay doors and fitted them to the frames.....


    I'm not 100% happy with them, but that's how they are ..... All left to do now is fit the top 'cap' to the lower sphere and do some touch-ups and fixes and the bottom half will be ready to marry to the upper ....:)

    And speaking of the upper half, I picked up the LED's I wanted and wired up the lightbox that will fit behind the cockpit windows.
    I lightly sanded the LED's to minimise the spot light effect of the lenses on them. This diffuses the light a bit.
    The LEDS were then simply glued into the light box with hot-glue.


    I connected everything together with the required resistor in the circuit....


    I then sealed up all the holes where light could leak out, with black RTV type silicone. I also hot-glued the wires to the back of the light box to provide a little more mechanical rigidity.


    The light colour and quality is much better in comparison to my test run earlier.


    I will post some more hopefully later this evening or tomorrow...

    Stay tuned.......

    (@zathros Insert 'WAVE' smiley here .....;))
    ASC Mclaren, bgt01, lyter1958 and 2 others like this.
  10. Revell-Fan

    Revell-Fan Co-Administrator Administrator

    Here it is:


    I have saved several threads when the look of the forum was updated, just in case something got lost during the transition... I saved a couple of smileys with them. ;)

    Thank goodness no-one was hurt in the accident. Phew, that was quite some start into the weekend.

    Great job on the Discovery! thumbsup
    Last edited: May 31, 2015
  11. Revell-Fan

    Revell-Fan Co-Administrator Administrator

    Well, I just needed a quote to add another smileys from days past for @zathros to upload it to the collection:
    20.gif 357.gif 35.gif roll1.gif violin1.gif 146.gif 36.gif 53_002.gif 68.gif agree1.gif
  12. DanBKing

    DanBKing Active Member

    YEAH!!!! :D:D

    Nice one R-F!
    Last edited: May 31, 2015
  13. DanBKing

    DanBKing Active Member

    I stamped my foot down at life and demanded some time for the Discovery..... I got my way ... :D

    I eventually got the window sub-assembly attached to the upper sphere........ Damn, what a nightmare that was.. :eek:
    It took me most of yesterday evening to get the thing fitted correctly. If it was out of position by the slightest fraction, it effected the whole sphere in shape or one way or another.
    I figured the best way would be to attach the two side frames first.... It took at least 5 attempts...... :sour:
    I used the beermat jig to accurately align the top and bottom edges.
    It was one hell of a fiddly job, with various curses included. :shamefullyembarrased:


    The texturing around the window is a little lacking in comparison to the studio model and I wanted to add that with raised detail. Also a handy way to help cover up some colour bleed above the window. o_O
    I used a spare copy of the relevant part and marked and then cut out a random pattern of slots....

    General_308.JPG General_309.JPG

    I made a set for above and below the window and then glued them on ....... I see that some of them are a little wonky, but I'll rectify that later on final touch-ups.

    General_315.JPG General_316.JPG

    I also fitted the top cap of the upper sphere and apart from final touch-ups, fitting of the light box, and detailing of the centre darker band, (which I will do after marrying the two halves of the sphere,) that pretty much completes construction of the two halves. All that is next to do, is join the two halves together, which, I hope, I will get done this evening at some point.

    On pre-planning for the next critical part of the build, the joining of the sphere to the neck, I devised a way of keeping everything round, perpendicular and square to its relation.

    UHU02 provides a 2 piece ring assembly to aid in attachment of the sphere. This ring must fit perfectly to the edge of the joining flange without any waviness, it must be perfectly round, the edge flat and must be kept perpendicular to the flange.
    Mmmm, I don't have enough fingers for that, so, JIG Time!:rolleyes:

    By placing the neck assembly with the joining flange downwards on a smooth surface, if you lightly press down on the spine coupling, it naturally splays out the joining flange to its maximum and uniform circumference. I then measured the diameter of the flange at 10,4 cm on my model.
    NOTE: The lengths of the provided ring pieces are too long and need to be trimmed and adjusted to perfectly fit the joining flange. Knowing the diameter of the joining flange, calculating the circumference, and therefore the (close to) strip length of 32,7 cm was simple. It makes a good starting point anyway.

    So, I cut out a 10,4 cm diameter ring from thick card. I used a compass cutter for this. (@zathros Did you ever make yours ?;))


    I then persuaded the thick card ring into the support ring. As it turned out, the thickness of the blade of the cutter compensated for the thickness of the paper of the support ring. :)
    I wasn't worried about any waviness on the back of the support ring, only the joint face was important..


    Then, on a flat surface, I pushed the ring assembly into the cut out hole of the thick card.....
    A perfect gluing jig.. :)


    I lightly glued up the tabs and the inside of the joining flange and placed this accurately into position over the jig and pressed down as before, (as when measuring, to splay the flange,) and let the glue tack up a bit.
    Before the glue dried too much, (because the jig is cardboard ...;),) I removed the jig by pushing downwards gently, away from the join. I left the inner ring in its place and it wont be removed either.
    Then, using something suitable to apply pressure in the correct places, in this case, a coffee pad tin did the job, I added a little weight, locked the cat out of the room and left it to dry for the evening.


    We'll see if that works out......... :rolleyes::cool:

    See you all soon, if all goes well ...... ;):)

    Last edited: Jun 2, 2015
  14. spaceagent-9

    spaceagent-9 Right Hand Man and Confidant

    what a really great job!! I see you use press molding also- I use a 2 liter flat bottom bottle filled with water, I adjust the weight by filling or emptying it. nice work on water bending those hatches too! you really make the model live. thank you for sharing your build.
    DanBKing likes this.
  15. micahrogers

    micahrogers Active Member

    The water forming, the press to shape everything is coming together beautifully on this.
    DanBKing likes this.
  16. zathros

    zathros SENIOR Administrator

    A fantastic representation of this fantastic ship. I hope your proud, I feel proud you represent this forum, and have blessed us with this build. :)
    DanBKing likes this.
  17. DanBKing

    DanBKing Active Member

    Thank you for the kind comments, I am also pleased with how well it is coming together!
    We are on the homeward stretch now!:)

    And this build is EXCLUSIVE to Zealot! I have not posted anything to any other forums, not even Facebook! :);)

    I did not quite manage to finish getting the sphere halves joined together last night. But, I should get that done this evening.
    I'll post some pics once it is done.
  18. DanBKing

    DanBKing Active Member

    There has been a marriage!!!!!!!!!!!!

    I finally have a ball!! :D:D

    I just have to fit the lighting tomorrow and do the detail work around the dark equatorial band, and it is complete.

    The neck assembly worked out well it seems and I test fitted it to the sphere. I have a lot of adjusting to do at the back of the sphere, but it is looking to be a nice fit.

    Whatcha all think of the current state of affairs then ?

    General_317.JPG General_318.JPG General_319.JPG General_320.JPG

    Earlier in the evening, I took the rest of Discovery model from under its protective wrappings to have a look at what repairs and other things that still needed to be done.
    But, when I got the halves of the sphere together, I just couldn't help my self, but to have a 'Just to see what it looks like' test fit of all the major sub-assemblies...

    General_321.JPG General_322.JPG General_323.JPG

    And I have now decided where the models permanent home will be. I just need to make the display case for it yet........ ;):)


    I'll be back over the next day or two with some updates.

    Take care, one and all.
    Sky Seeker, bgt01, Revell-Fan and 2 others like this.
  19. Revell-Fan

    Revell-Fan Co-Administrator Administrator

    This is HUUUUUUUUUUUUUUUUUUUGE!!!!!!!!!!!!!! :)
    DanBKing likes this.
  20. DanBKing

    DanBKing Active Member

    Yeah, that's for sure!
    Model length, 120cm.
    The length of the display case will have to be no more than 130cm long to fit on top of the cupboard where I want it.
    With the lighting ideas that I have for the display case, it should really make the model look fantastic up there.
    Almost made to measure! ;):)

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