|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.