task was to find accurate and detailed drawings of the intricate and futuristic cut outs all around the brain structure. An email to the B9buildersclub got me answers and dimensional drawings.
of the brain is built from 3 laminated layers of 3/32 Hobby plywood, glued together with a 20 minute epoxy on a very flat
surface. I bought 3 12x48 inch sheets of the plywood at the local RC airplane
hobby shop, and layered the wood sheets by placing 2 12x24 inch pieces down first, then applying a thin layer of epoxy resin,
then laying the next two sheets rotated 90 degrees, then the final 2 sheets, with epoxy rotated 90 degrees. This ended up giving me a 24x24 square inch sheet of approx 1/8, very flat plywood, which would fit 4 brain
top/bottom pieces (giving me an extra piece if I messed up on one. Using the
pattern I made from the drawings I got, I cut out 3 identical pieces, A top, bottom and middle. I then took the middle piece and cut all but 3/8 of it out giving a piece that is used for the structure
of the brain and allowing a place for the solid top piece to sit on. As it turns
out to get the best fit for the brain construction, the middle support piece sits 1 inch above the base plate, so I cut a
number of 1 inch long hardwood blocks and started gluing.
of the brain was made from a pattern piece stuck to 1/64 hobby plywood veneer. The
pattern printout was glued to a piece of construction paper and carefully cut out, then CA (super glue) glued to the wood. Mistake!!!, now I had to cut out all of the detail patterns again, way too much work. The brain sides were made by gluing the pattern to 2 layers of construction paper using
spray on paper/scrap booking glue. I then cut out the pattern with my exacto
knife (long task).
the spray glue had set I pre bent the brain side panel for the hard radius at the back of the brain in a simpe
jig cut from a 2x4 scrap and let dry over night. The brain front and sides are
then glued using CA glue to the frame. Because the construction paper is soft
and I wanted more thickness, I laminated ¾ oz fiberglass to the sides and re-trimmed the cutouts using fine files. This gave it a strong hard structure. I bought cast eye lenses from one of the club members that
sells them as an aid to other builders.
The top plate is
made from 2 sheets of 1/64 ply laminated using 2 part epoxy. This makes the top plate thin, light and rigid.
Prime, Sand, Prime, Sand and Paint
was next. Make sure to mask off all of the areas you dont want paint getting into.