Dalek Bill Dalek Dirk The Scarf Mod

The Eye

Dirk's eye is made very much like Bill's. One difference is that I cut the eye disks using a router rather than a hole saw. The hole saw tends to melt the edges of the acrylic, whereas a router produces a nice clean cut (it's in contact with the plastic for much less time). I also cut 2", 3.5" and 4" disks, rather than the specified 2", 3" and 4" disks. This produces a circular profile when seen from the side rather than a diamond shaped one.

Bill's hole sawn eye disks
Dirk's routered eye disks
Here's the jig I made for cutting the eye disks
and the set of disks I made with it. Another advantage of this method is that you don't need a new hole saw for every disk size you want to make...
Notice here that the threaded rod that goes through the eye pivot is mounted 1/4" above the centre line.

With Bill I had it go through the centre, and then I had to arrange for two mounting bolts each going 1/4" into the pivot, which was much more complicated.

This new arrangement is much simpler, and you can't see the difference from the outside.