Where does this wire go?

I filled the corners with bondo and did my first pass at sanding. It is getting closer to looking like a skirt. Also, you may notice some wood on the top of the skirt toward the front and two blocks on either side. This is because the bottom of the base for some reason lifted up and the top isn’t level. These blocks are to make the next layer start from a level position. I’m probably going to put some sort of filler between the skirt and shoulders. the front came out okay so I should be able to salvage this skirt.

Here is a picture looking down on the power chair through a hole I cut in the top of the skirt.

I’ve taken two pictures of my 2005 NSD Dalek build. The first pcture shows the x-factor twist that goes in to the Dalek front panels. I think this x factor twist makes a Dalek look like a Dalek.

The second picture is the rear section of the Dalek skirt. Notice there are large gaps between panels. This is probably due to not accounting for the thickness of the panels. I’m not too worried about it, I plan on fiberglassing the joints anyway. I’ll fiberglass from the inside and then use some wood filler on the outside to fix all the gaps.

First test was pretty good. We found that the front wheels might need to be downsized since they rub against the front wheel openings. I will probably go with 6″ to replace the 8″. Also, the front wheels have tubes and were practically flat. I’m going to get sold tires. I don’t know if you could tell in the video, but my lawn isn’t exactly flat and the fact we could move at all on the law bodes well. We expect we we will be driving mostly on pavement or floors, but it is nice to know we can go across the lawn if needed.

We had stopped working on the Dalek after I crushed my toe. Well the toe is long healed. We stopped at the point where we were trying to figure out out to mount the base to the frame. Well, I got the right side almost mounted. I need a longer bolt but it shouldn’t be too much more work to get it finished.

Picture of Dalek Fuzzball being created. Notice one panel isn’t quite right?

My brother came over and we finished cutting all the pieces of the skirt. Then we went and test fitted them. Guess what! There were several that were so badly cut as to be unusable and needing to be re-cut. The worst part of it is that those panels were ones I did by myself .

Thats right 4 more panels. I have 5 total out of 11. This weekend coming up I’m hoping to knock out a few more. Maybe I’ll get lucky and get them all done so I can see fuzzball taking shape.

This is the first of the skirt panels. Bob convinced me to start with the panels first and then the inner frame. This is the back pannel.

Back panel of skirt.

We got the second side of the base done. We are doing two pieces and then bolting them together.

Next time we will be starting on the skirt frame.

Both pieces of the base side by side.