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Dave Stapley
Dave Stapley
Posts : 954
Join date : 2010-02-16
Age : 44
Location : Wrexham
http://www.soundclick.com/thegonzohouse

My Voicebox Cover construction Empty My Voicebox Cover construction

Thu Mar 14, 2013 9:37 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

My Voicebox Cover construction 1diffu10

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

My Voicebox Cover construction 2inser10
My Voicebox Cover construction 3paint10

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

My Voicebox Cover construction 4baseb10

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

My Voicebox Cover construction 5sixmm10

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

My Voicebox Cover construction 6baset10

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

My Voicebox Cover construction 7topsr10

Now we glue the side overlays on

My Voicebox Cover construction 8basec10

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

My Voicebox Cover construction 9finis10


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

Dave
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My Voicebox Cover construction Empty Re: My Voicebox Cover construction

Thu Mar 14, 2013 9:47 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.
Dave Stapley
Dave Stapley
Posts : 954
Join date : 2010-02-16
Age : 44
Location : Wrexham
http://www.soundclick.com/thegonzohouse

My Voicebox Cover construction Empty Re: My Voicebox Cover construction

Thu Mar 14, 2013 10:03 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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My Voicebox Cover construction Empty Re: My Voicebox Cover construction

Thu Mar 14, 2013 10:29 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,
Dave Stapley
Dave Stapley
Posts : 954
Join date : 2010-02-16
Age : 44
Location : Wrexham
http://www.soundclick.com/thegonzohouse

My Voicebox Cover construction Empty Re: My Voicebox Cover construction

Thu Mar 14, 2013 10:38 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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dgacampbell
Posts : 56
Join date : 2013-02-14
Age : 47
Location : N.Ireland Name: Dan

My Voicebox Cover construction Empty Re: My Voicebox Cover construction

Thu Mar 14, 2013 11:44 pm
Very nice work! Cool
HalloweenKnight
HalloweenKnight
Posts : 451
Join date : 2010-05-18
Age : 49
Location : Finland

My Voicebox Cover construction Empty Re: My Voicebox Cover construction

Fri Mar 15, 2013 2:12 am
Looks awesome Smile
stepheneire25
stepheneire25
Posts : 578
Join date : 2010-10-19
Age : 43
Location : Ireland

My Voicebox Cover construction Empty Re: My Voicebox Cover construction

Fri Mar 15, 2013 8:28 am
great insight, brilliant work! Smile
pbryant_knight
pbryant_knight
Posts : 1700
Join date : 2010-01-15
Age : 45
Location : Newcastle Upon Tyne

My Voicebox Cover construction Empty Re: My Voicebox Cover construction

Sun Aug 25, 2013 5:57 pm
Never seen this write up before mate. Must have somehhow missed it. Great stuff Thumb up
Dave Stapley
Dave Stapley
Posts : 954
Join date : 2010-02-16
Age : 44
Location : Wrexham
http://www.soundclick.com/thegonzohouse

My Voicebox Cover construction Empty Re: My Voicebox Cover construction

Sun Aug 25, 2013 6:06 pm
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.
stepheneire25
stepheneire25
Posts : 578
Join date : 2010-10-19
Age : 43
Location : Ireland

My Voicebox Cover construction Empty Re: My Voicebox Cover construction

Sun Aug 25, 2013 6:30 pm
Great work Dave
What else do you make
Dave Stapley
Dave Stapley
Posts : 954
Join date : 2010-02-16
Age : 44
Location : Wrexham
http://www.soundclick.com/thegonzohouse

My Voicebox Cover construction Empty Re: My Voicebox Cover construction

Sun Aug 25, 2013 10:42 pm
Just overlays mate, haven't got time to continue with electronics at the moment
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My Voicebox Cover construction Empty Re: My Voicebox Cover construction

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