40” Enterprise D (movie version)
2/2010 through 10/2010
Last Update: 10/19/2010
Similar to our previous conversion of a Sovereign Replicas kit, this second build will reflect the changes made to the ILM miniature for the movies it was featured in. Given the changes that were made to the original miniature, this kit needed a multitude of revisions, starting with all the main windows and grid lines. The start up pictures below reflect our revisions to imitate the revised ILM miniature. After getting the main saucer revised, the secondary hull was given the same treatment as well using magnets to attach the belly section. Similar attachment is planned for the saucer. Like before, we are using a translucent blue and translucent red for the nacelle body and “Bussard ram-scoops”. Below right shows which windows have been blacked out (opaqued) as yellow stencils.
Critical to the central support is the armature, designed by our lead modelmaker, Mike Asanuma, and sent out for water-jet cutting in aircraft grade aluminum. The secondary hull is then screwed and epoxied onto the backside of the armature, with a post receiver capable of minor axis adjustments. Special concerns are the fiber-optics that have their own pipe system through the wings to allow for easy insertion. Another major revision involved re-sculpting the rear nacelle top details. A new master pattern was created, then molded to cast an exact duplicate for the opposite nacelle. The stand is a near copy of our TV version, with the addition of “movie” added between U.S.S. Enterprise D and Star Trek.
Joining the saucer to the secondary requires us to not only mate with the neck (dorsal), but also integrate the forward armature, made from several laser-cut acrylic stringers. These stringers attach to a machined aluminum plate that has adjustment screws, allowing for an upward pitch to reach level. Further development of the nacelles will show the use of magnets to hold the ram-scoop to the main body, allowing for easy servicing of the central light bar. The lighting system for the main saucer and secondary consist of warm white LED ribbon light mounted onto laser-cut acrylic support rails, each made to be removable.
Once the hull castings have been cleaned up enough to fit tightly together, the base coat (primer layer) is applied all over. Several window areas are then re-masked to for the next phase of painting, allowing for a quick light test. Note the windows in the neck area. Since the next work effort is concentrated drawing the 4 color layers artwork, necessary to produce the vinyl cut masks, it was a good time to go ahead and finish the miniature globe and stand chevron. A concentrated effort was made to match the world in First Contact where the Enterprise D saucer crash lands into. Weeks later we arrived at the completion of the first set of paint masks – starting the nacelles, in order to preview the 4 colors prior to committing to the entire ship scheme. From these maps, laser-cut vinyl masks were made to hold back each successive (additive) color layer. The second t last picture on the right shows the first color layer masks which are applied to protect the darkest blue, when the second medium blue layer is sprayed on.
The first two pictures (as well as the previous last one) show the 4 color result, confirming that these color choices are harmonious and correct to proceed with through the remainder of the painting process. The center picture shows the highly detailed upper secondary body and wing topside developed to move onto the secondary hull. Right two pictures show the first color layer laser-cut masks being applied to protect the dark blue color, similar to the nacelle painting process. Medium blue is next in the process.
A "before and after" paint sequence application to the secondary hull and neck areas. Removal of all the vinyl paint masks reveals the windows as well as the complexity of the 4 color paint scheme. Front deflector dish bowl is completed with white "scattering" added. Note how seamless the magnetized belly plate is with respect to the surrounding lower wing area.
Onto the lower saucer surface, with a quick check of the vinyl masks, using a printed illustrator map. The completed nacelle with front "bussard ram" attached. Central lower saucer masks (silver) and outer banks being applied. Last photo shows the completed saucer with all masks removed to reveal 4 color paint scheme.
Attaching the nacelles and finalization of the connecting paint work. 2nd to left shows the lower saucer inner banks lifeboats decal placement. Mark Büchler applies the first round of lifeboat decals. Last photo shows the nearly complete lower belly plate with dry transfer rub on graphics (pennant and transporter pads) applied.
A final detailing, by adding the dry transfer lower saucer registry, and pennants on the nacelle topsides. Registry numbers to the wings (pylons) and well as the upper saucer. Kurt Zendler swabs the lifeboat decals on the upper saucer.
