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 My Voicebox Cover construction

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Dave Stapley



Posts: 954
Join date: 2010-02-16
Age: 35
Location: Wrexham

PostSubject: My Voicebox Cover construction   Thu Mar 14, 2013 3:37 pm

I was asked how i build my voicebox covers so i took a couple of pictures kind of showing how it all goes together

First we start with laser engraving the inserts and cutting the diffusers to go behind the inserts



Next i paint the text in the inserts, which takes a couple of days as it needs around 3 coats




This is the 12mm Base from the back in which the voice modulator window is glued in first



These are the 5mm standoffs in which the side inserts sit, these are mounted from the front of the voicebox to give the sides the extra height



Now the Center Matt overlay is glued on (Center overlay and 5mm Sides are shown to the left for comparison)



Here are the top overlays shown as a set (The center one we glued on in the last picture)



Now we glue the side overlays on



And the painted inserts mount from the back and are glued in, finishing the voicebox cover as below.




Hope this helps anybody that's thinking of having a go of doing there own,

Dave
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http://www.soundclick.com/thegonzohouse
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PostSubject: Re: My Voicebox Cover construction   Thu Mar 14, 2013 3:47 pm

Very very cool there Dave. Thanks for lifting the lid and revealing your technique.

One query/request though, how easy would it be to make it modular so that the voicebox lense or the pursuit lense could be swapped as and when? I'm thinking of maybe being able to swap between kitt/karr or red/blue pursuit....maybe even pilot/equaliser vbox too...

Fantastic.
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Dave Stapley



Posts: 954
Join date: 2010-02-16
Age: 35
Location: Wrexham

PostSubject: Re: My Voicebox Cover construction   Thu Mar 14, 2013 4:03 pm

Steve, to be honest im not sure with replacing the lenses, i use tensile glue which fuses the plastic, if only a small amount of tensile was used then they would quite easily pop out. but would only be swappable from the rear as the front overlays stop them from being in the wrong postion

Hopefully i make sense
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http://www.soundclick.com/thegonzohouse
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PostSubject: Re: My Voicebox Cover construction   Thu Mar 14, 2013 4:29 pm

Dave, makes total sense lol...

Maybe then the answer would be to make the whole unit swappable...i.e. have multiple units and swap the whole unit over as and when you feel like it.

Cheers for your reply, it looks great,
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Dave Stapley



Posts: 954
Join date: 2010-02-16
Age: 35
Location: Wrexham

PostSubject: Re: My Voicebox Cover construction   Thu Mar 14, 2013 4:38 pm

Steve, i actually made these units so they mount from the front of the dash, so i can actually pull mine out and stick another in its place, as my car was a KARR replica at Knightcon, then i swapped it over a few days later to be KITT for comic con
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http://www.soundclick.com/thegonzohouse
dgacampbell



Posts: 56
Join date: 2013-02-14
Age: 37
Location: N.Ireland Name: Dan

PostSubject: Re: My Voicebox Cover construction   Thu Mar 14, 2013 5:44 pm

Very nice work! Cool
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HalloweenKnight



Posts: 374
Join date: 2010-05-18
Age: 40
Location: Finland

PostSubject: Re: My Voicebox Cover construction   Thu Mar 14, 2013 8:12 pm

Looks awesome Smile
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stepheneire25



Posts: 573
Join date: 2010-10-19
Age: 33
Location: Ireland

PostSubject: Re: My Voicebox Cover construction   Fri Mar 15, 2013 2:28 am

great insight, brilliant work! Smile
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pbryant_knight



Posts: 1516
Join date: 2010-01-15
Age: 36
Location: Newcastle Upon Tyne

PostSubject: Re: My Voicebox Cover construction   Sun Aug 25, 2013 10:57 am

Never seen this write up before mate. Must have somehhow missed it. Great stuff Thumb up

___________________________________
One man can make a replica
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Dave Stapley



Posts: 954
Join date: 2010-02-16
Age: 35
Location: Wrexham

PostSubject: Re: My Voicebox Cover construction   Sun Aug 25, 2013 11:06 am

Thanks Peter, they don't look to bad at all, very proud of these as they took quite a while to get right and perfect.
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http://www.soundclick.com/thegonzohouse
stepheneire25



Posts: 573
Join date: 2010-10-19
Age: 33
Location: Ireland

PostSubject: Re: My Voicebox Cover construction   Sun Aug 25, 2013 11:30 am

Great work Dave
What else do you make
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Dave Stapley



Posts: 954
Join date: 2010-02-16
Age: 35
Location: Wrexham

PostSubject: Re: My Voicebox Cover construction   Sun Aug 25, 2013 3:42 pm

Just overlays mate, haven't got time to continue with electronics at the moment
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