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McGann
Hey Gang,

So onward to the final Part VI of the TARDIS Console restoration. So we're picking things up a few days after Pt. V. For the home stretch, the main goals were to finish last connections to mount the last of the flooring, replace/remake all of the missing switches, correct the lean and secure the rotor, make sure the new sound replacement drive worked, troubleshoot the little things and clean everything while giving it all a beauty sweep including painting, minor repair and aging the hand crank.


Photo by Scott Sebring

More Pics and info

So we had a lot to do and very little time left to do it in to make Gallifrey One! So we dove in head first with a lot of the little things that needed looking after.


The Console ready for the final round of tweaks and upgrades

First Paul had done a great job getting all of the cords and main power strips and the sound drive all cleanly mounted inside the Doctor's bag for easy access as well as making sure none of it got tangled on itself.








Power strips, cords and sound drive now secured and ready within the Doctor's bag

Then Paul secured all of the top layer of Doctor's tools down with nicely hidden zip ties to make sure this top 'shelf' could be removed easily and none of our tool replicas would go flying about anywhere.






Tools now zip tied down for easy removability

Paul also added some flair to the tools with some antique gears/bits he found at Michael's in the scrapbook section!






Antique gears and bits from Michaels

Next we noticed that the console would shift a bit when we moved it around, literally twisting a bit on the base central column. So we maneuvered it back into the correct position and then we locked it into place with a few carefully placed bolts drilled into the bottom. It was now tight and unmovable.








Securing the base from twisting/shifting

Paul also spent time adding silicon to the half-spheres on the top/bottom parts of the rotor to prevent light bleed as well as hitting them both with a new coat of paint (with some dry brush detailing) so they now looked back to spec and ready for time traveling action.




Rotor base and top now lined with silicon to prevent light bleed

Then Paul spent a lot of painstaking time smoothing and re-enforcing the leg joins to the foam sculpted "claws/globes." He accomplished this with a lot of putty 9000 and sculpty, all carefully sanded down by hand to give the smoothest finish possible.








Claws now reenforced with sculpty and putty

Then we noticed one of the castor wheels under the hexagon base was sticking badly and creating a skid mark when we tried to movie it. We tilted it up and discovered one of the discarded screws from an earlier day had hit the floor and gotten lodged inside of it! We removed the screw and now it was good as new. Minor crisis averted.


Problem with base wheel


Tools for the job


Team TARDIS on the case

Meanwhile, we discovered that the PVC tubes we'd used as mini-hoods on the white toggle switch board for the jewel lights burned due to the heat generated. We couldn't have this hazard, so we replaced these tubes with Copper ones which I re-glue din with hot glue and silicon. Now they still looked great and it was much safer.


Copper tubes replacing the PVC ones

Paul and Brian then worked at securing all of the final wires and connections with hot glue and zip ties to make sure everything stayed as snug as possible for future transport.






Securing final connections


Power plugs/cords re-secured and zip tied

Next we had to look at replacing the missing switches. We tried the original plan of using some sanded down screws with some sculpty molded over them but these just didn't quite cut the mustard.


1st aborted attempt to make switches from the screws and sculpty

We then had the eureka moment thanks to Paul's wife who noticed as he was trying to get the shape right with the sculpty that the switches resembled long craft beads one would normally see on a beaded curtain. She'd nailed it. Paul found perfect sized craft beads that would work as switch replacement at Michael's, the arts and crafts store.




Craft Beads - new switch source

For the top of the switches we'd complete the look using some small silver nails we got at Osh Hardware. Cheap and effective, they would do the job nicely.




Nails for the tops of the switches

The next step was to painstakingly sand down each of the craft beads to remove the lines and make them all a nice ivory color which was a nice match to the white toggle switches. This was done with use of power tools and a hand polish to finish it up.










Sanding down the beads to make the new White toggle switches

Once the new switches were ready we re-secured the panel back into place with screws. We double checked all the electronics still functioned properly and the new copper tubes were good to go. Once confirmed, then each craft bead was carefully glued into place on the panel with 5 minute epoxy. Each small nail was then placed into the 7 switches/beads also with the same epoxy. This was fairly easy and cured well overnight so they were rock solid and ready for TARDIS control action the next day.












Gluing the beads and nails into place as the new white toggle switches with Epoxy


White Toggle swtiches back in place

For the black switches, the now sanded beads would have to be cut down by about 1/3rd to match the original size. This was done easily with a dremel tool.




Cutting Beads down to 'black toggle switch' size

Once completed, each of the seven beads had to be re sanded down to create a better shape with a belt sander and a lot of extra sandpaper polishing by Brian and myself.




Sanding down the beads into the Black Toggle Switch shapes

For the single missing yellow 'puck' switch on the 'readout' panel we wanted to make a mold of one of the existing switches and make a resin copy. But we ran too low on time to do this and getting even one of the switches off was proving more difficult than we''d thought. So we went for option 2 which was to simply make a new switch out of sculpty. Paul took a first crack at this and then Brian sanded the new puck down to size to match the others.




Yellow Puck replica switch made from sculpty


Puck being belt sanded down to size

While we worked on the switches, Paul completed the rather arduous and tedious task of mounting the panel power strips and cords inside the Column again to prevent anything from getting tangled or disconnected during transport. This was accomplished mainly with well placed velcro strip but was quite a pain due to the limited angles one had to physically reach inside the thing and do any fine tuning or finessing of placement.










Mounting Power strips inside the column

Once finished we went over the piece for last minute fine tuning such as hot gluing the round grating light cover into place.


Light cover hot glued back in place

Then we straightened out the radial dials so the lights actually matched where the colored stain glass was and hot gluing these back into place.








Hot gluing the Radial Dial back in place straightened out

A neat feature we found while exploring the Console was what Brian dubbed the TARDIS 'dip stick' - one of the buttons actually pulled out and resembled the oil change gauge on a car.




TARDIS "Dip Stick"

A few missing thumbscrews were replace don the Radial Panel from screws present underneath the console already- cheap and accurate, easy solutions like this were no brainers when they presented themselves.


Replaced thrumbscrews

The reflector underneath the radial dial readout was replaced to give it a brighter display.


Replaced reflector under the Radial dial

The green gel underneath the oval light was also put back in place and heavily cleaned out for dust and cobwebs with a Qtip.




Replaced Green Gel for Oval Light and Cleaned/Dusted out

Brian then tested out the fans which were mounted inside already. He'd rigged it to the side corner button on the radial panel. Up for off and pushed down for on. A nice side effect: The fans gave a nice low hum to the TARDIS which gave the piece a bit of extra life!




Knob hooked up to the fans- on and then up for off

With all of this now complete, we were ready to put the last two sections of underside TARDIS 'flooring' back on and close it back up.




Ready to re-mount the underside TARDIS Flooring




Getting ready to hot glue/silicon the last of the connections




Folding last of the electronics back up




Securing final flooring piece in place

This was really a three man job, two to place and hold it in position while he third had to speedily secure it in place with the canadian screwdriver bit. We noticed additional spots for screws where there were none so we added a few extra to keep it extra secure.






Putting the flooring back in

Once this was all put back together, Brian properly mounted the Berilyium Chip into the underside of the phone toggle flip panel so it could be brought out and easily switched on during the convention.






Berilyium Chip now connected and attached into the actual console.

Extra cleaning still had to take place. We spotted some guck and grime (the remains of an old Wasp nest on the underside of the console) that had to be carefully scraped away.




Scraping off some dirt and guck under the console

Once this was all done we had to tackle the rotor. Mainly we wanted to correct the smal lean it had and make sure once it was on it would stay secure.


Re-working the Rotor mount

We noticed part of the problem was a screw/washer sticking up from the plate which was not giving the rotor an even surface to sit on. So Paul drilled out a hole into the rotor base to compensate.


Pre-drilling holes or dips into the wood so it will rest evenly over some screws sticking up.

Then the wood which was designed to hold the rotor in place was recut and shifted higher (where it not sat to reveal the bottom "teeth/mesh plate" inside the base.




Cutting wood to place it closer and higher in the base to better secure the rotor

Also Brian took this opportunity to hot glue in the last of the LED lights in place (these had a tendency too want to pop out of the sockets) that were toward the top of the console which was another worry now gone.


Hot Gluing last lights in place

Back to the switches- both the black toggle switches and the now sanded down puck piece had to be painted to primer before their final coats.


Painting Switches


priming the puck

Once the curved wood pieces were re-situated inside the base it held the time rotor much more secure and it sat fairly even now.




Re-situating the wood curves to correct the leaning rotor

Paul and Brian struggled to think of a way to hold the rotor down without creating more headaches taking it on and off until they hit on the idea of creating wood clamps which would effectively twist on and off the small circular lip the wood of the lower rotor base afforded them. This was a slight pain to implement but once in place it worked like a charm.






Making and adding wood 'clamps' to twist on and off and hold Rotor in position underneath

The final touch was adding a large washer to one side to correct the last of the Rotor leaning problem.


Hidden large washer corrects the slight leaning problem

Once done we placed the rotor on and gave all of the lights a fresh test to make sure everything still worked smoothly.








Re-testing lights to make sure everything still works



http://www.youtube.com/watch?v=9kFi3YTZ9ck

We also re-tested the new sounds which got delivered in the nick of time by Irma and the Ride Tones folks and dropped onto one of our new back-up spare drives. Due to space we had to sacrifice the TVM Theme song for the Big Finish theme but otherwise they all sounded great and we were back in interactive TARDIS sound business. A Big thanks to the Ride Tones folks for helping to save the day on that score!


Ride Tones drive - Replaced and fixed!

I took a moment to take inventory of all the spare parts- wood, small and large halogen bulbs, piano wire, vent, light gels and mounting brackets we would offer for donations at Gallifrey One.






TARDIS Parts people can buy for a certain donation at Gallifrey

Then we had to tackle the 14 or so half-spheres that had fallen off the base of the TARDIS over the years in storage. Tedious... but this was easily done with epoxy and hot glue and in several cases, added screws to really make sure they stayed put.






Beginning the process of epoxying/hot gluing the half spheres back onto the base column

Because these had a tendency to fall off we hot glued around the joins of ALL of them. While doing this we discovered we were one half-sphere short. One had gone missing in the intervening years.






Finished re-applying the broken off half-spheres - all save one!

We would replace the missing final half-sphere with a wood sphere from Michaels that was just about the same size. It would be measured to the others and cut in half (and hallowed out!!!) to be ready to go on the base.




Re-enforcing Spheres with Hot Glue

The hot glue created a gloss texture that stood out though and we had to hide this by re applying a layer of murky grey paint over all of them to match the base and take the curse off of it.


Taking curse off the hot glue gloss with acrylic paint

The cut wooden sphere was then gooped up with some glue and paint to match the textur of the others and let to dry before final painting.


Cut wooden sphere, gooped up to match texture with acrylic and glue

Finally it was painted to match and applied with epoxy glue.


Adding in the final replacement half sphere

The black toggle switches then got spray painted with gloss black paint.


Finished painted black toggle switches

These were then carefully glued into place on the Star panel again with 5 minute epoxy, and cut down nails dropped into place with more epoxy. The final result was pretty awesome and very close to the real deal. After a night of curing these were pretty secure and ready for more TARDIS control functions!




Black Toggle switches glued back in place with epoxy

We noticed the Enigma keyboard was loose at this stage. So it was given a thorough clean with some WD-40 and then hot glued and screwed back into place.


Enigma Keypad cleaned with WD40 and re-fixed with screws and hot glue

The half-sphere wasn't the only thing missing. One of the three underside gold grating vents was also missing. Originally we thought we'd have to go without but at the last minute Paul called in a favor and was able to make a silicon mold of the 2nd grating.






Grating- prepping and making a silicon mold

Using this mold he created a plastic resin copy of the grating making up the third missing one.




Grating- resin copy

This copy then had to be thoroughly sanded and cleaned up by machine and by hand.


Sanding copy for painting

The paint job to match was trial and error, using several gold spray paints until finally the right finish was found using a dull gold and some gold leaf which was dry brushed on by Paul to replicate the look of the originals fairly well.






Painting the Grating

Both of these gratings were then put in place underneath the console (where the fans were now blowing) using hot glue and a few strategic screws.


Both Gratings put in place with hot glue and screws

Now came the daunting task of giving the console a big beauty sweep. And it really needed it as over the years the edges had taken a lot of ding, nicks and paint scrapes. Here's a number of detailed shots showing the damage.












Console nicks and Dings - Before

We weren't sure how we were going to solve this. None of us were really painters- at least not in the meticulous 'matching-to-color' sense. So we called in Kelly Delcambre and his assistant Rachel. Kelly was a friend of ours who worked in prop restoration and had a good eye for color matching. He literally saved our bacon on this one. Although it helped both were Doctor Who fans and were pretty excited to work on the Console (and see Paul's Dalek in the process!)
















Painting the TARDIS for touch ups

They only had time to give it a 'quick n' dirty' fix for 4 hours 2 days before the con but the work they did on matching the paint and hiding all of the flaws was really amazing.








Painted TARDIS- After

Afterwards they graciously helped us on a few other finer points such as painting/aging the Hand Crank.




Unpainted Hand Crank


Painting Hand Crank

The first try was good but we felt it was a bit off, re-consultig the Regeneration Boook we saw the handle needed to be jet black gloss (something Paul himself handled on his own) and the metal handle needed to be really rusted and aged.


Hand Crank paint- stage 1

Rachel took a second crack and really nailed the look. Paul went in afterwards and sanded down the edges to give it a worn look.




Painting Hand Crank for more aging

Kelly then hand matched the yellow color tone of the other puck switches to match on the missing switch handle which we then glued into place.


Painting Yellow Puck replacement to match others




Painted and replaced Puck switch

The paint job was really stellar and added a lot of character to the console.




Hand Crank Stage 2

Paul knocked out the new black Hand crank knob in no time.




Painting Crank Handle Gloss black


Putting new gloss black handle on and distressing the edges for more wear

At last the new Hand Crank was ready for display!


Finished Hand Crank

Paul took the time to paint the central button for the Magnetic Clamp at the same time as well.


New Black Button for the Magnetic Clamp

The last job Kelly and Rachel tackled was to paint over the grey putty/sculpty on the legs and match it to the rest of the legs/base with that greenish/grey murky color. Again this was a fast job (and done on a freezing Wednesday morning I might add) but it all came out great and hid the patch job Paul did on the legs quite well.










Touching up paint chips in the base and hiding the grey sculpty on legs

The final result was pretty impressive for a quick 4 hour job. We had a nice talk with Kelly regarding further restoration and improvement options to really take the dings out and further 'beautify' the prop which we plan to do in a few weeks time after the convention.




Legs After

Then we repaired the broken PVC Flashlight holder on top with hot glue while re-securing the other seven spots and adding the painted tops to each to help disguise them once the top was placed on.


Fixing the top rotor Flashlight holders with hot glue and hammering in the painted tops

Then we took the rotor apart and I gave it a really good interior cleaning with some windex and vacuum cleaner while Paul gave the TARDIS a good wipedown with a wood lamanent safe swiffer.






Cleaning the rotor

The Console was now DONE and ready for display at Gallifrey One - and only JUST in the nick of time. (I'll get into the logistics of how we got the console there and that set of challenge sin my Gallifrey con report) For the weekend of Feb 17th-19th at the LAX Marriott attendees of Gallifrey One got the special treat of seeing this in person and having thier photo taken with it!


Ready For Gally Attendees

While at the convention it was a real joy to see the look of awe and happiness on the 300+ fans faces who got thier photo with the TARDIS Console. That right there made all the hard work and time worth it.

For anyone who got their photo with the TARDIS Console and have still not received their photo via email, please look for you picture on one of these links:

FRIDAY
http://www.flickr.com/photos/8028861@N06/sets/72157629075559956/

SATURDAY
http://www.flickr.com/photos/8028861@N06/sets/72157629440429827/

SUNDAY
http://www.flickr.com/photos/8028861@N06/sets/72157629075728818/

Click on original size, then it takes you to the page where you can download your picture.


Team TARDIS! Photo by Scott Sebring


Inspector Space Time doesn't care for this TARDIS Photo by Scott Sebring


Daleks in the TARDIS! Photo by Scott Sebring

We also got visits from several guests and VIPS including: Phil Ford, Richard Dinnick, Michael Troughton, Gary Russell, Nick Briggs, Caitlin Blackwood, Inspector Spacetime, Daphne Ashbrook, Yee Jee Tso, Eric Roberts, Philip Segal, and of course, Paul McGann!




Eric Roberts visits the console Photos by Scott Sebring


Caitlin Blackwood Photo by Scott Sebring


Nick Briggs Photo by Scott Sebring

McGann and Segal were especially pleased to see the old girl and were the most in awe to see it restored. They both thought it had been junked years ago so it was quite the pleasant surprise. They were happy to share stories and take photos with it again. It was extra cool to see the '96 TARDIS Crew (Ashbrook, Tso, and McGann) together and back at the controls on Sunday! It was a highlight of the con for Paul, Brian and myself!


Mcgann, Ashbrook and Tso reunite to fly the TARDIS Photo by Scott Sebring


Team TARDIS with the 1996 TARDIS Crew! Photo by Scott Sebring

There have been a number of write-ups about the console and a very cool video posting which you can see/read here:

http://www.kasterborous.com/wordpress/2012/02/paul-mcgann-and-the-tv-movie-tardis-console/

http://www.badhaven.com/tv/tv-news/gallifrey-one-doctor-who-con-coverage/

http://www.craveonline.com/videos/featured/183603-doctor-who-convention-coverage-gallifrey-one-2012

http://news.thedoctorwhosite.co.uk/paul-mcgann-reunited-with-tardis-console/

http://www.kasterborous.com/wordpress/2012/02/paul-mcgann-and-the-tv-movie-tardis-console/comment-page-1/#comment-21514

http://blogs.laweekly.com/arts/2012/02/tardis_console_1996_doctor_who.php

http://www.youtube.com/watch?v=R8Gy04OlpeQ&hd=1

http://www.hypable.com/doctor-who/2012/02/21/doctor-who-fan-restores-1996-version-of-tardis-control-panel/

http://geeks.thedailywh.at/2012/02/21/refurbished-tardis-console-of-the-day/

http://travelingthevortex.com/?p=1957

http://www.raingeek.com/2012/03/07/doctor-who-news-restoring-a-tardis/

http://www.shadowproclamation.net/blog/2012/03/article-37-whats-behind-door-number-2/

and... the Doctor Who News Page!

http://www.doctorwhonews.net/2012/03/restoring-tardis.html

More on the TARDIS Console and pictures in my full Gallifrey One 23 Con report which I will be posting in three parts later this week!!!!

TEAM TARDIS - The Bios:



PAUL SALAMOFF

Paul Salamoff is a twenty-plus year veteran of the film industry. He has found success as a Writer, Producer, Film Executive, Comic Book Creator, Author, and originally as a Special F/X Make-Up Artist.

Born in Natick, MA, he was raised on a healthy diet of sci-fi and horror from the age of five. After high school, he moved to California to attend film school at USC. Salamoff parlayed his obsession for genre filmmaking into a successful run as a professional Special F/X Make-Up Artist. In his years doing FX, he worked on over forty films, ten television series, and numerous commercials.



His Film and TV writing credits include THE DEAD HATE THE LIVING, THE ST. FRANCISVILLE EXPERIMENT and ALIEN SIEGE. He was recently hired to write the high-budget SINBAD: ROGUE OF MARS for Morningside Entertainment. He is also author of two non-fiction books: ON THE SET: THE HIDDEN RULES OF MOVIE MAKING ETIQUETTE and THE COMPLETE DVD BOOK: DESIGN, PRODUCTION AND MARKETING.

As a Comic Creator, Salamoff is the writer of a number of Comic Book Series including the wildly popular VINCENT PRICE PRESENTS, ROGER CORMAN PRESENTS BLACK SCORPION, PUPPY POWER: BO OBAMA and LOGAN'S RUN: LAST DAY and LOGAN'S RUN: AFTERMATH both written with William F. Nolan. He is also author of the critically acclaimed graphic novel DISCORD and the upcoming THE CAST OF DOCTOR WHO bio-comic.



In 2005 Salamoff became Vice President of Production for David Lancaster Productions working on WES CRAVEN'S THE BREED and HOLLOW MAN 2. After a successful merge with BOLD Films, he became their Vice President of Production and worked on such films as LEGION, BOBBY and STARSHIP TROOPERS: MARAUDER. After leaving Bold, he accepted the position of President of Production for Rat Bastard Productions working on the festival darling DOWN FOR LIFE.

Having been involved with THE ACADEMY OF SCIENCE FICTION, FANTASY & HORROR FILMS for over twelve years, he produced the 22nd, 23rd, 33rd, 34th and 35th Saturn Awards. Salamoff has also produced Video Game TV/Web Development videos and Trailers for G-Net Media. Working on such high-profile projects as THE ADVENTURES OF TINTIN, BULLETSTORM, MAFIA 2, MASS EFFECT 2, GEARS OF WAR 2, DEAD SPACE and the upcoming RECKONING: KINGDOMS OF AMALUR



BRIAN UIGA

Brian Uiga has been building gadgets and props since 1996, when he saw the Dr. Who TV Movie, fell in love with the show, and was compelled over the next four years to build a complete TARDIS toolkit, as well as other props and costumes from the classic era of the series.



Over the last decade, his other prop replica projects have included: a set of the puppet robots from “Mystery Science Theater 3000”, a fully working Herbie, the Love Bug car, a gadget laden James Bond's BMW from "Tomorrow Never Dies", and Horace, the Hate Bug car. These Celebrity Replica cars are kept busy most weekends during the year at charity or police events with a group of TV and Movie cars at www.starcarcentral.com.

Brian is currently working on a "Super Pursuit Mode" Knight Rider KITT car alongside these TARDIS Console repairs. He feels fortunate to be able to restore and add life to he centerpiece prop from the film that inspired him to start tinkering 15 years ago.



When not pursuing his hobby of replica cars and props, Brian has worked as a Special Effects Supervisor and Producer of sketch comedy. He currently works as a mechanical engineer designing precision optical equipment for film post production and restoration. He is a graduate of the UC San Diego with a degree in Mechanical Engineering.



BOB MITSCH

Bob Mitsch is a graduate of the University of Southern California with a degree in English and Screenwriting. In addition, to having five years experience as a marketing copywriter, he has spent an additional five years working in Television Post Production at a local PBS affiliate, Riot! Santa Monica and Starz Media.



When not pursuing the above, Bob's hobbies include writing, films and costumes. In his youth, he wrote and directed over a dozen student & fan films and also acted in a handful of Los Angeles independent theater productions. Bob dove into the cosplay convention scene over a decade ago with a replica of a childhood favorite - the Greatest American Hero's super suit. A handful of other superhero/science fiction characters followed before Bob tackled the daunting project of putting together costume replicas (and props) for all 11 incarnations of the Doctor, plus several Villians such as the "Revenge" Cyberman and a VOC Robot.



He is the organizer of the Costume Panel Track for the Gallifrey One Convention, Co-Moderator of dw-cosplay on livejournal as well as the writer/host of the 8 part How Who Are You? Dr. Who Marathon segment series for KTEH TV in the fall of 2009. Recently, he was ecstatic to be featured along with his friends in costume on Matt Smith's iphone during the Xmas 2011 Graham Norton Show.


On Matt's iPhone as Hartnell

He has found the cosplay hobby a lot of fun and a rewarding way to meet other fans and new friends. He has been a fan of Dr. Who since he was 6 years old. (And for the record Tom Baker will always be HIS Doctor.)



Thanks for reading! This part pretty much wraps up the current stage of restoration. Down the line we're going to be looking at adding a motor to the Time Rotor to make it move and look at improving a few of the quick fixes like improving the yellow puck switch replacement, really giving it a nice beauty pass for paint, wax and finally some preservation steps to keep it in it's current condition. When we do, I'll post about it then for sure.

It was a pleasure to see all the fans (and VIPs and Stars) who saw this beautiful prop at Gallifrey One last weekend. The looks on everyone's faces made these past three months worth it!

I'll be back with a full report on Gallifrey One 23!

EDIT: This report is now up please check it out to read more about Gally and the Console here:

http://honorarydoctor.livejournal.com/19040.html - Thu / Pre-Con
http://honorarydoctor.livejournal.com/19355.html - Friday
http://honorarydoctor.livejournal.com/19814.html - Saturday
http://honorarydoctor.livejournal.com/19814.html - Sat Night Masque
http://honorarydoctor.livejournal.com/20071.html - Sunday

-Honorarydoctor

Comments

ametistova
Feb. 27th, 2012 11:06 am (UTC)
NICE! We are waiting for full report!

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