Here is my install experience:
First make sure you get a snack, this is going to be a long install.
My apprentice is curious and somewhat willing to help, but lacks focus.
So, Im going solo on this journey.
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The instructions in the booklet are dead on perfect.
I cut a hole in a small box to make a work surface in order to not smash the motor terminals or break off the wires.
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Remove the tub and the dalek.
Remove the light post.
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Unplug the flasher lamp wire.
Cut off the 30 year old zip ties to separate the wires.
You wont need the light post again, so put it aside for something else..
Take a look at your Dalek.
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Rip his head off! This was a little worrisome as I didnt know what to expect.
But without gripping his nose, you can get your fingers in between the head and body.
With a lot of pressure and pulling, it pops right off.
The glue appears to be hide glue or titebond, definitely not a plastic glue.
Im surprised that the heads dont actually fall off, they are not really securely glued on.
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The glue easily scrapes off with a plastic razor blade.
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After a little cleaning, its time to install the head support.
Drill a hole in the top of the head?
The 3/32" hole recommended on the top is too small to get the screw in. 7/64" is perfect. 1/8" would be too lose for a snug fit.
Next the support bracket:
The mounting screw goes on the nose side to avoid any conflicts with the center shaft and lamp support.
I opted to initially install it to the rear in order to get some measurements, then move it to the correct location later.
The booklet says to line it up 1/2" from the edge and the support will hang down at a pretty extreme angle.
This is approximate, and will work, but not centered perfectly in my case.
After looking at it and measuring the centers, 9/16" from the edge was perfect.
I also bent the support so that it was level.
Bending it makes it way easier to mount it on to the shaft. and takes the pressure off the plastic edge to keep it from cracking off.
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I also had to put a small bend in the lamp post to keep it away from the bushing with the locking pins.
Its best to install the bushing at this point.
Slide bushing onto the shaft, locking pins facing upwards, adjust the lamp post to give it clearance by bending it a little.
I put a small "S" bend in it.
Install the head and screw it down lightly. Its best to not over tighten the head screw at all during any part the installation.
You will install it many times and dont want to wear out the plastic.
Slide the bushing up, engage the locking pins, tighten the set-screw. That's it.
Next, try to fit the body on the mechanism!
Its fitting a square peg in a round hole!
Take your time with this.
Its not listed in the instructions, but the opto-interrupter goes in the front with the adjuster brackets on the right.
You can do it the opposite but it appears that way in the pictures in the booklet.
This position makes the unit sit far forward from the Dalek's original position. Its not ideal.
Flipping it reverse as TaylorVA did sets the unit further back but requires a bit more material removal to get the mech inside the Dalek body.
Either way, I figured that I might have to elongate the hole in the backbox top to get it where it was from the factory.
Knowing this, I decided to go with the booklet position and rework the hole in the backbox a little..
Along with everyone else I had to cut a couple "V" notches in the base to get the corners of the mech to go in.
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I used a big flat file to remove the material a little at a time as needed.
There is no official template as all heads are slightly different, but they all go in similarly. Just whittle away at it until it goes in.
I also had to adjust the mounting holes in the body quite a bit.
Mostly side drilling them as needed.
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After spending a couple hours on this, finally it will just "pop" in.
The adjusters on the mech allow for side-to-side and up-and-down movement but no forward and back adjustment.
Forward and back is accomplished by rotating the mech, you get about 1/4" of adjustment.
I doesnt seem like much, but its plenty really.
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My height adjustment was close enough from the factory setup.
The screw in the head ends up 1/16" from hitting the underside of the tub.
I could have lowered it another 1/16" but that would involve the height adjustment screws, and i didnt want to reposition my center as it was pretty close.
After 3 1/2 hours of slow steady work (with no help from the cat) you should get a perfectly centered shaft.
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All that's left is to mount the head and check for level.
You can level the body via the mounting nuts.
The head can be carefully bent into position if needed.
Then you can admire your 4 hours work:
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Installation onto the game is pretty straight forward and pretty easy for testing.
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The wire placement guide in the booklet really helped out a lot!
In my case I would have had to move the led board 1/2" towards the front (as suggested in the booklet) and then move the tub further forwards to keep the Dalek's nose from hitting the tub.
After doing a temporary install and getting some measurements, I opted instead to elongate the hole in the backbox 3/4" to the rear and 1/4" to the left to center the Dalek back to where it was initially.
It was fairly straight forward.
I just shoved a rag in the hole and perf drilled a series of 1/8" holes and side drilled them out.
The end looked like a rough keyhole cut, but the mech base plate covers it completely.
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Total time, working slowly and methodically 5 hrs, with a 30 min lunch break.
It was well worth the time spent.
One can certainly do it all in about 2.5 hours after doing it once or twice.
I cannot describe how much nicer this unit is compared to that silly $100 servo system that breaks every 6 months and doesn't interact with the game...other than a flasher hook-up.
This is the real deal!
Its not for the novice builder, but its not terribly difficult either.
It just takes a bit of time to get it right.