Today's work: Gun Box

[kproche]

Here are the photos from today's project: the "gun box" that the ball-joint-mounted gun and plunger arm come out of.

Parts for TDKs Gun Box The Gun Box is where the plunger arm and gun emerge from the Dalek. Here we have (in 1/4" Plywood): Top Two sides and Front (with holes for the ball joints) Bottom

Another view of the Gun Box parts The 6 blocks are 3/4" square hardwood to which I'll screw the plywood. This will give me nice strong, square joints

The assembled box, front view I cut the holes for the ball joints using a circle tool with my Dremel.

Side view of assembled box There is lots of distortion from the iPhone lens. The back end of the box (to the right in the photo) is actually square; only the front face is angled.

Assembled Gun Box, inside view Here you can see 3 of the hardwood blocks. I need to shape two more to match the angles between the top, front face, and bottom, so I can stabilize the long edges in the center of the box

Inside view of assembled gun box It isn't real obvious, but if you look closely you can see I used the sanding roller on my Dremel to chamfer the inside edge of the hole for the ball joint. This lets it fit better, and let me even out the worst distortions I got in my (newbie) circle cutting with the Dremel.

Test fit of redwood ball joint into aperture on box As you can see, the fit is pretty good. This is the ball I'll be drilling the well into for the wide end of the plunger arm.