Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - Printable Version +- Forums (https://www.studioscalemodelers.com/forums) +-- Forum: Index (https://www.studioscalemodelers.com/forums/forum-623.html) +--- Forum: Studio Scale Replica Builds In Progress (https://www.studioscalemodelers.com/forums/forum-678.html) +--- Thread: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch (/thread-2260.html)

Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 05-13-2014 This has been in the works for quite a while. A few years ago I had the opportunity to study and measure a copy-casting made from the original studio miniature (courtesy of a good friend). I began making patterns for a scratchbuild and worked on them as time permitted. Earlier this year I wrapped up and delivered a battlestar body build for a client and I finally had time to get some work done on this shuttle project. It took over two months to develop the patterns, mainly because I wanted to include an authentic looking interior. As far as I know, this has never been done before. Even after pouring through screen captures and original set blueprints, it was very difficult to tell exactly how they configured the cabin set. I finally decided to just build it full size (in CG) and see how well I could match what we saw on screen. This turned out pretty well. Plus, I learned quite a bit about the original set in the process. While creating this mockup, I was able to derive patterns for the instrument panel, console, pilot’s seats, and passenger seats. Those will be further fine-tuned prior to 3D printing. All that remains to build are the joystick controls and some misc. small details. Once I was satisfied with the mockup, the next step was to see how well it would fit inside the studio miniature. Not surprisingly, it did not fit at all. The set is much too narrow — and WAY too long — to be placed inside a “real” shuttle. As a result, I was forced to shorten it dramatically. Then, I had to find a way to “cheat” the width to get the seats far enough outboard so they were underneath the windows. While I had to make quite a few modifications in the process, the results still look pretty good. It may not be a perfect match to what we saw on screen, but I feel it is more than close enough to proceed. Please see attached for some renders of the full-size set mockup and also the modified version test-fitted inside a (CG) replica of the studio model. RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 05-13-2014 Because of the weird angles and rather tricky shape, I chose to build the model in styrene. The bulk of the structure is 1/8 styrene sheeted in 1/16 styrene panels. Custom-cut plates will be installed on top of that. I'm guessing the original model was carved from foam and skinned in Bondo and then plated with thin styrene panels. As far as BSG ships go, this one is very difficult to get the shape just right. I totally admire anyone who attempts to build one of these. The studio model had a multi-point armature. I wanted to include this as well. Unfortunately, adding an authentic interior meant sacrificing the front mount. So, this replica features a bottom mount, rear mount, and two side mounts. No top mount was added. The interior structure and acrylic "core" armature is complex enough already! The model mounts on a steel 5/8" diameter rod. The armature tubing is sized just right to make for a nice, easy slip fit. I added a hidden set screw, accessible from below, so the rod can be locked in place inside the model. RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 05-13-2014 Like I said, the shape is really tricky to get just right. The original studio model had a removable cockpit top hatch. The frames around the windows are extremely thin. To make sure the shape would be just right, I designed custom stringers in 3D and had them printed in ABS. It would be extremely difficult to build a structure from scratch that had the proper compound curves for a clean, tight fit. RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 05-13-2014 We had another long build session last week. This is taking a bit longer than most projects because we are building not one but *three* models at the same time. So, each time we finish an area, we have to do it all over again -- and then again. The first model's rear section is finished and plated. The corresponding front section has been fully framed and we're in the middle of skinning it. Before that could begin, though, we had to "marry" the front and rear sections together permanently. There's no going back now! LOL Because the original studio model was likely carved/sculpted, recreating it using frames and skins is really quite tricky. There is a lot of twisting in the skins as the angles change from one area to another. Still, we think it looks pretty good so far. This project was made possible by the generous assistance of several people. They include (in alphabetical order): Jon Billings Mark Bradley Phil Curl Jeff Garton Gene Kozicki Richard Lindstrom Rob McFarlane Mike Salzo Photos of this build can also be seen on Facebook. Thanks for looking! BTW, if you are interested in the original Battlestar Galactica filming miniatures, check out a new Facebook group here. RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - LastBattlestar - 05-13-2014 Damn, I thought that was a list for people wanting a kit.... RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 05-14-2014 No kits! RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - JAWS - 05-14-2014 Looking good Charles! Can't wait to see that interior you designed. Oh & beautiful engineering on the hulls mate, as usual. RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 05-14-2014 Thanks! RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - dbhs - 05-14-2014 Really spectacular work, Charles. Having built this from Mike's kit I can understand how difficult it would be to scratch build this shuttle. You'll really enjoy completing this. Look forward to more updates. RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - LastBattlestar - 05-14-2014 Well, I don't need a kit. When you are at the laser cutters next time, just type in four instead of three and send me the parts. I can build it. Mike RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 05-15-2014 Well now, that would be a kit then, wouldn't it? This model has been incredibly difficult to build -- even more so than a Galactica head section (and I thought *that* was complicated). It's also been expensive. Let's just say the materials alone for building the body cost more than the entire resin kit that's out there. Some of the structural parts are 3D printed for each model. They can't be molded and cast because resin warps and shrinks and is generally not dimensionally stable over time. I don't trust resin for anything other than surface details and non-structural items. In the end, I think it's well worth the effort and expense because you just can't beat the quality and craftsmanship of a well-built structure that is built to last. RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - dbhs - 05-15-2014 Words to live by: "In the end, I think it's well worth the effort and expense because you just can't beat the quality and craftsmanship of a well-built structure that is built to last." -Charles Adams RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 05-15-2014 RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 06-02-2014 Here's another update. (Keep in mind, we don't get to work on this every week due to juggling multiple projects/priorities.) The first shuttle body has been fully plated and all that remains are touch-ups and fitting the cockpit roof. It will need some final "preening" and a coat of primer before delivery. My friend Richard Lindstrom made a crate for it, so that is ready to go. The second and third models are also coming along well. The rear section is complete for one and the second is ready for plating. The front structures are built and skinning has begun. Once the first model has been delivered, progress may slow down as we will be switching gears to start building not one but *two* studio-scale battlestars! RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - LastBattlestar - 06-02-2014 Looks good. No detailing? Mike RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 06-02-2014 Not for the first one -- body structure only. The second and third shuttle models will be built. detailed, and painted. RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 06-11-2014 The first model is almost ready for priming and final delivery. The second and third models still have a ways to go. The cockpit windows and removable cockpit roof may be the most complicated and tricky part of the entire build. Just like the original, the entire roof comes off with the windows attached. In 1978, they were made up of two layers of very thin styrene. Ours are built the same way. We had to come up with several "tricks" though to add stiffness and increase the structural integrity of the assembly. It turned out remarkably well. Unlike the original, this model has a detailed cockpit and even the inside of the roof is detailed to match the interior set built for the show. It will be fully illuminated as well. This created enormous challenges in terms of gaining access to install and service the lights. We had to come up with a totally unique way of attaching the assembly to the rest of the ship. It mounts using magnets and screws. The screws are hidden underneath what was the "front mount cover" on the original studio miniature. RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 06-11-2014 The center portion of the roof is also removable (unlike the original). This allows greater access to the inside of the model. To take advantage of this feature, I designed a separate interior "rear compartment" behind the main cockpit and passenger area. On the show, there was a rear hatch at the back of the set on what would be the port side of the ship. In the pilot episode, this doorway led to a separate area that was just barely visible on screen. (In later episodes, this same hatch would seem to lead directly outside the ship!) This replica is the only model I know of that has anything like this. So far, we've successfully built out the structure and details of our rear compartment and test fitted everything inside the model. RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - Wombat - 06-11-2014 Looks amazing, Charles.. Fantastic job not only designing it all to start with but the builds themselves. It really does look amazing and will look just incredible (that cockpit in particular) when all finished and lit. Very cool mate!! RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - darkimmitator - 06-11-2014 WOW !!! RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - JAWS - 06-12-2014 Niiiiiiice Loving that cockpit Charles! Excellent work. RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 06-12-2014 Thanks! I've created two new short videos highlighting details of our TOS Galactica Shuttle replica. Each presentation is less than a minute. I started creating these clips in order to illustrate specific design features for potential clients. It was so much fun making them that I decided to use this format to show off more of our work. Exterior Details: Front Mount Cover: http://youtu.be/7s6XaHFs9S4 Interior Details: Rear Compartment http://youtu.be/HqjPB2KYPjo RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 06-16-2014 A few more pics. The first prototype model has now been primered and is almost ready for final delivery. Some minor touch-up is basically all that's left to do. RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - LastBattlestar - 06-16-2014 That looks great guys. What sort of primer are you using? Nice umbrella. I want to see a pic of Charles without some sort of protective item on. And now you have time to mow the lawn. Mike RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - Wombat - 06-18-2014 Looks bloody good seeing it at this stage. The shape looks perfect and as good as one could ever ask for really. Nice work both of you!! RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 06-18-2014 Thanks Phil!! Very funny, Mike. The sun was so bright, I couldn't see the camera's viewfinder without that umbrella (and note that filmmakers do this sort of thing all the time which is where we got the idea). We are using Duplicolor lacquer-based primer. It's really good stuff. A special thanks to Steve Neill for recommending it. The paint I was using before (Rustoleum) kept clogging up. It tried to ruin everything we sprayed with it. With that said, we learned the hard way that there are two types of Duplicolor primer and one should choose carefully. Their *filler* primer is awesome stuff -- fills scratches, builds nice and is very easy to sand. On the other hand, use caution with their "sandable" primer. The good news is it's almost as fine as Tamiya primer but much less expensive. I would use it to prime greeblies. The bad news is it dries so hard that it's more like a steel coating. It doesn't sand well at all. In fact, it destroyed our expensive sanding sticks! The coating was so durable I was forced to *scrape* it with a knife in order to get rid of the lines where we taped it off. I'm not kidding. . . RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - JAWS - 06-18-2014 I want to see more interior pictures! RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 06-18-2014 Uh, there aren't any -- at least not right now. The first model isn't getting an interior (well, not yet anyway). So, that will have to wait until ours are further developed. Sorry. . . RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 08-05-2014 This project had to be moved to the "back burner" for a while, but Shuttle #1 is finally ready to be delivered! Thanks for looking. . . RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - Wombat - 08-05-2014 Thats a nice looking piece even without greeblies on it.. Good job there fellas! RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - star-art - 08-05-2014 Thanks! RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - KrokoHunter - 08-07-2014 Awesome work, buddies ... Soooo have to built one of these one day .. either Scratch or the JAWS kits .. really wanna scratch them ... but with so little time, so many projects, and way too many distractions, I might end up doing the kit RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - Jake88 - 08-24-2014 I love that shuttle and your work is fantastic! I'm in hog heaven watching this thread! Thanks RE: Studio-Scale TOS Battlestar Galactica Shuttle from Scratch - JAWS - 08-25-2014 Nice work as always Mr Adams!