Head Frame
  Head Cladding
  Body Frame
  Body Cladding
  to be continued...

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Well, the console I built is the K.9 console, so there has to be a K.9. It's as simple as that.

I've actually been waiting for someone to produce some good plans and now Gene Fender has done just that on the Doctor Who Prop Builder's Club. The plans are here (not on the MSN club).

I've never done this before, but I'm going to attempt to clad this K.9 in 22 gauge sheet steel over a wooden frame. I built a prototype a while ago though.

I started by producing a 1:1 scale template for the side of the head, which I've reproduced here as a PDF. I should mention that Gene has updated the plans slightly since I made this, and I haven't had time to remake the PDF, so the nose is a little off.

I sprayed across the template onto a piece of plywood to produce two sides for the head. I then attached width-wide pieces to separate these to start the head structure.

The sides were joined together front and back at the correct width, but of course this didn't produce the right width in the middle. Even some bracing across the middle wouldn't bend the plywood enough to reach the correct width. So I began building up the sides to the correct profile with the application of some shaped shims.

I then wrapped the frame with construction card to form templates for the metal sheet.

Mmmfl wffl

I've really no idea if this is going to work, so I'm just going to press on and see.

The current plan is to fold the metal around the horizontal parts and glue the verticals on with a glue that will glue metal. If that doesn't work I'll screw the sides on and cover the screws with Bondo (P38?).

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