flauzus
07-21-2009, 01:21 AM
My latest project has been to make the Aperture radio from the video game Portal for my kids to use as a cosplay prop at Otakon 2009.
http://img169.imageshack.us/img169/4749/image41.jpg
The first step was to get some real clear screen cap’s of all the orthogonal views of the radio.
http://img225.imageshack.us/img225/9215/radioviews1.jpg
Then I created a true to scale 3D model of the radio. The software I use is SolidWorks:
http://img210.imageshack.us/img210/5294/radioviews.jpg
From the model I created a set of detailed drawings from which the parts can be fabricated:
http://img146.imageshack.us/img146/1589/overalldims.jpg
Including the cross section slices at 1" elevations.
http://img149.imageshack.us/img149/6217/stackx.jpg
These cross sections were printed out full scale and used as templates to cut pieces of 1" foam.
http://img198.imageshack.us/img198/5867/im001271.jpg
The pieces of foam were then laminated to form a core:
http://img195.imageshack.us/img195/638/img00011x.jpg
The core was then sanded to shape (I kept a spare core).
http://img196.imageshack.us/img196/397/img00013wrz.jpg
A layer of fiberglass was then applied to the core. A cavity was carved out for the electronics
http://img381.imageshack.us/img381/7185/img00024.jpg
The electronics were taken from a Polk Audio PC speaker set
http://img200.imageshack.us/img200/7836/im001270.jpg
The amp was wired to a mini MP3 player that will loop the music from the game. A pair of 9 volt batteries in parallel powered the amp and LEDs.
http://img210.imageshack.us/img210/2328/img00025z.jpg
The front of the radio is a sandwich of a masonite face plate, printed transparency, acoustic fabric and a Plexiglass backing illuminated by multiple LEDs. The original idea was to use translucent cyan acrylic and or cyan LEDs, but I didn't have time to acquire these before my deadline so I used what material I had on hand.
http://img401.imageshack.us/img401/7093/im001273.jpg
The shell was wet sanded and painted. Some small blemishes were intentionally left behind since the radio in the game had marks from wear and tear.
http://img193.imageshack.us/img193/861/im001264.jpg
The electronics and the face plate were mounted vertically in slots routed into a plywood base. The MP3 player was mounted with Velcro for easy maintenance.
http://img195.imageshack.us/img195/4438/im001265a.jpg
The antenna, knob and mount for the potentiometer/switch were machined from scraps of plastic. The pot was also salvaged from the Polk Audio speaker. The antenna is also used as a push button to work the MP3 player mounted directly below it.
http://img195.imageshack.us/img195/4733/im001277.jpg
Other details included the use of custom water slide decals for the bar code on the back,
http://img188.imageshack.us/img188/9328/im001268.jpg
an Aperture logo stenciled on the face plate,
http://img204.imageshack.us/img204/9914/im001278.jpg
and an Aperture Laboratories sticker on the bottom
http://img248.imageshack.us/img248/6632/im001267.jpg
The unveiling at Otakon 2009 on 7/17/09 (making a note here, huge success)
http://img338.imageshack.us/img338/1749/otakon.jpg
http://img169.imageshack.us/img169/4749/image41.jpg
The first step was to get some real clear screen cap’s of all the orthogonal views of the radio.
http://img225.imageshack.us/img225/9215/radioviews1.jpg
Then I created a true to scale 3D model of the radio. The software I use is SolidWorks:
http://img210.imageshack.us/img210/5294/radioviews.jpg
From the model I created a set of detailed drawings from which the parts can be fabricated:
http://img146.imageshack.us/img146/1589/overalldims.jpg
Including the cross section slices at 1" elevations.
http://img149.imageshack.us/img149/6217/stackx.jpg
These cross sections were printed out full scale and used as templates to cut pieces of 1" foam.
http://img198.imageshack.us/img198/5867/im001271.jpg
The pieces of foam were then laminated to form a core:
http://img195.imageshack.us/img195/638/img00011x.jpg
The core was then sanded to shape (I kept a spare core).
http://img196.imageshack.us/img196/397/img00013wrz.jpg
A layer of fiberglass was then applied to the core. A cavity was carved out for the electronics
http://img381.imageshack.us/img381/7185/img00024.jpg
The electronics were taken from a Polk Audio PC speaker set
http://img200.imageshack.us/img200/7836/im001270.jpg
The amp was wired to a mini MP3 player that will loop the music from the game. A pair of 9 volt batteries in parallel powered the amp and LEDs.
http://img210.imageshack.us/img210/2328/img00025z.jpg
The front of the radio is a sandwich of a masonite face plate, printed transparency, acoustic fabric and a Plexiglass backing illuminated by multiple LEDs. The original idea was to use translucent cyan acrylic and or cyan LEDs, but I didn't have time to acquire these before my deadline so I used what material I had on hand.
http://img401.imageshack.us/img401/7093/im001273.jpg
The shell was wet sanded and painted. Some small blemishes were intentionally left behind since the radio in the game had marks from wear and tear.
http://img193.imageshack.us/img193/861/im001264.jpg
The electronics and the face plate were mounted vertically in slots routed into a plywood base. The MP3 player was mounted with Velcro for easy maintenance.
http://img195.imageshack.us/img195/4438/im001265a.jpg
The antenna, knob and mount for the potentiometer/switch were machined from scraps of plastic. The pot was also salvaged from the Polk Audio speaker. The antenna is also used as a push button to work the MP3 player mounted directly below it.
http://img195.imageshack.us/img195/4733/im001277.jpg
Other details included the use of custom water slide decals for the bar code on the back,
http://img188.imageshack.us/img188/9328/im001268.jpg
an Aperture logo stenciled on the face plate,
http://img204.imageshack.us/img204/9914/im001278.jpg
and an Aperture Laboratories sticker on the bottom
http://img248.imageshack.us/img248/6632/im001267.jpg
The unveiling at Otakon 2009 on 7/17/09 (making a note here, huge success)
http://img338.imageshack.us/img338/1749/otakon.jpg