Level 3-3: Fit Weapon

17 Dec

Subject Delta's Drill Reference

Greetings readers and fear not, we’ve been working like busy little bees on Subject Delta‘s drill. With the tedious task of  papier-mâché behind us, we’ve started working with some fresh, new materials and we’ve made some excellent headway! For a lovely change in pace, Daniel’s going to start us off as he describes working with plywood to create a handle for the drill.

Drill Handle TracedNow that we had the main body of the drill constructed, the question was, “How do we make it easy to hold and carry while giving the rest of the drill a sturdy and supportive base?” At first, I thought about using a single dowel rod but it didn’t give us much to attach the rest of the drill to. Then it dawned on me that a plywood base with holes cut out of it to form a handle bar would be perfect. It’s light weight and would give us plenty of surface area to anchor the drill to. Thankfully, Home Depot carries smaller, individual sections of plywood that are perfect for small projects and simple home repairs. We had hoped that they could cut the circle out for us at the store, since we didn’t have anything more than a simple hand saw at home. Unfortunately, they couldn’t and, for a couple that relies on public transportation, renting the tools were completely out of the question so we decided to tough it out.

Makeshift Saw HorseTracing the Drill BaseCutting shapes out of wood can be difficult without the proper tools and a steady work surface. Our end table wound up as the steady work surface in this instance. Sara wasn’t hovering and nervous at all… Using the base of the drill we traced a circle onto the plywood, we laid a towel down and I got to it. Rather than killing myself by trying to cut the shapes free-handed I decided to use the drill to cut some starter holes. I then drilled a continuous series of holes along the lines I wanted to cut; this way my hand saw would have less wood to cut through.

Drilling guide for Base Drill Holes Guide Hand Saw for Drill Base

30 minutes and a blister on my finger later and I had the basic shape cut out. Though the basic shape was there, it was rough around the edges and just a smidgen too large to fit the opening of the cone. Lucky for me, and my blister, my drill bit set came with a couple of handy-dandy sandpaper rolls attachments which I used to smooth out the edges and grind down the excess around the outside edge. Here’s the end result! — Daniel

Finished Drill Base

You might think that the next step would be to attach this lovely new base to the cone, but you would be wrong. Don’t feel bad though, I was wrong in this assumption too. But that’s only because I get stuck thinking about the next step instead of three steps ahead like my super-smart husband. So, here he is again to explain the very strange picture below.

Drill Base AnchorIf you’ll check out our reference photo you’ll see that at the base of the drill there’s a fan-like mechanism with rotating blades backed by what looks like a cheese grater. Rather than attaching the base and then constructing the mechanism, I wanted to build this “cheese grater” part of the drill  and use it as a bridge between the body of the drill and the arm strap system. Sort of like that song; the drill body’s is connected to the wood base, the wood base’s connected to the “cheese grater,” the “cheese grater’s” connected to the fan-like mechanism, the fan-like mechanism’s connected to the arm strap system and so forth.

When it came to attaching the fan-like mechanism section, I first thought about using thin individual strips but then realized that if I used one larger, continual band of material that it could be used to attach the fan-like mechanism to the base. I could then emulate that “cheese grater” look by drilling holes into this band and they would peek through the blades. Since I had left over cone, I decided to use those scraps, hence you see orange “cheese grater.”

The left over cone material was strong and pliable, perfect for securely attaching the fan-like mechanism to the base; but if you’ll notice, it does not contour as perfectly as I would like, leaving a slight gap at the back. This is due to the angled design of the cone.

Thankfully, this  “cheese grater” band will be housed inside the fan-like mechanism section, masking the gap. Plus, this gap section will be on the underside of the drill where no one will see it anyway.

Metal Outside Cone Bending the Metal

I attached the  “cheese grater” band to the drill-base with four wood screw (two on each side) and the drilled the series of holes. I bent the tabs of the fan-like mechanism section to give it that fan-blade look and then fitted it over the “cheese grater” band and attached it with two bolts with cap-nuts. — Daniel

Drill Base Together

And voila, we have the base of our drill. Next we shoved that base into the papier-mâchéd cone and with a couple of wood screws we secured it.

 Subject Delta Drill with Base

But we weren’t done here. No siree! Next, we needed to create a bar and strap system that would connect the drill all the way up Daniel’s arm. But I’m afraid that you’ll have to wait for next week. Be sure to check back next week! – TCG

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