i need to build a flying saucer

[stevetx19]

for...uh....work.

Construction will begin around May 20th, so i have some time to plan it. This is where is need your help; what is the best way to build a flying saucer that meets the following requirements?

-Does not need to fly.
-Will be placed in an area away from electricity, so lights and sound are not a priority. If a creative way to illuminate the craft is possible, i'm willing to try it.
-Needs to be big enough to be impressive, but we don't have room for a full scale. I'm thinking in it can be about 10' across and maybe 5' tall.
-Basic flying saucer shape-ring surrounding a globe with a tripod legs to stand on.
-Needs to be lightweight, easy for one(fairly strong) person to handle the weight even if the size makes it awkward to carry.
-Also needs to be built cheaply. I have access to lots and lots of free cardboard and paint. If plastic or metal can be used, great, but i don't have a large budget. It needs to be more sturdy than a solid cardboard saucer would be. I'm thinking a mix of materials.

So....any ideas?

[geeza]

Styrofoam insulation panels and a fine tooth saw (and maybe a rasp).

[T-Bird]

Hi.

Another vote for styrofoam, but do Yourselves a favour and DON'T USE A SAW of any kind.
Hot-wire cutter is the easiest and environmentally-safest method.

Personally, if I was faced with such a task, an inflatable one would be my choice. May not fit into Your budget.
You could always modify a surplus weather balloon though.

Regards
Sam

[bongomania]

+1 to not using a saw on styrofoam. For the outer ring/wing part, one option to try would be getting several 4' x 8' sheets of thin (like 1/8") wood or composite, like cheap paneling, and cutting wedge shapes out of it that could be screwed or riveted together to make the overall curved and angled form.

Example--make trapezoidal wedges that rivet together to make this shape:



Then bend the edges together, and it becomes this shape:

[machine gewehr]

Go to Area 51 and ask for one nicely,I'm sure they'll help,they're cool people.

[Downunderwonder]

You need an electronics wizz to make you a flashing LED array for the rim. Not too difficult and a few (cheap) flashing LED will run forever on a borrowed (free) car battery.

Look into paper mache, papier mache whatever. It's pretty durable once it's painted.

[TomA1234]

Originally Posted by machine gewehr

Go to Area 51 and ask for one nicely,I'm sure they'll help,they're cool people.

I think those ones might be a little too heavy for one person to carry.

[stevetx19]

i think i could get a better looking product with foam than with paper mache, though i don't have the workspace to make the mess involved with foam. i'm looking into paper mache on a wire frame....

[geeza]

Originally Posted by bongomania

Example--make trapezoidal wedges that rivet together to make this shape:
IMG
Then bend the edges together, and it becomes this shape:
IMG

I don't get how the wedges become dog shaped.

Originally Posted by TomA1234

I think those ones might be a little too heavy for one person to carry.

Not if you turn on the anti-gravity.

[Auzzie-Phoenix]

cardboard to make preforms, industrial spray adhesive, some wonderflex (heat moldable plastic that can be shaped over and over and over), gesso, aluminum spraypaint, and a few led strips or pc casemod glowtape, and a few 6v lantern batteries.

The cardboard or metal coat hanger preform will lend strength, shape your wonderflex around it using a heatgun (it can make bell curves, etc... great stuff), coat in gesso to smooth finish for painting. Sand down if need be, drill holes for wiriring, coat in spraypaint, affix lights, run wires.

Won't be strong enough to support bodyweight, but should be strong enough to stand on its own, and be light enough to carry with one person.

[stevetx19]

Wow, that wonderflex looks to good to be true. I'd love to use something like that, but some quick research makes me think i will blow my budget very quickly. What would be the advantage of putting gesso down before paint, instead of sanding?

this guy built something similar in his yard for Halloween, mostly out of pvc pipe, which i think will also be too expensive.

Invasion Santa Clara 2000 - Flying Saucer Construction

[Auzzie-Phoenix]

wonderflex is thread infused plastic, it has a bit of texture to it... the gesso is to smooth it out and let the paint hold better. sanding the gesso coat down just removes any rough spots.

I went back and looked at your size specifications, and with a 10 ft. dia. and 5 ft. height, that's a LOT of material. Meaning that yes... wonderflex would soak up a ton of budget. It's not a cheap material for large projects. A large sheet is roughly 40x50 in. and would cost $40-60 depending on your supplier for it. It costs a lot because there aren't a lot of people making it, so supply is rather tight.

Your best bet will probably be screen door mesh covering a frame. And then use a filler material to fill in the mesh for painting.

[geeza]

How 'bout chicken wire and mylar film?

[kingpin2512]

Chicken wire or something similar with paper outside that you use a sharpie to color?

[stevetx19]

my budget can handle more than sharpies...

mylar might work...

[BogeyBass]

This is a real cheesy drawing....not to any scale

But i was thinking of a flat profile where you can get as many pieces out of a single piece of material.

So using cardboard or possibly 5mm luan plywood used for flooring substrate and build a frame.

Then maybe use cheap painters drop cloths to stretch and staple over the frame.... and then paint and add details with paint.

as far as lighting maybe somebody already has a low wattage 12volt dc adapter so you can plug.....110volt ac 4 watt florescent party bulbs to a car battery.



here is just a basic idea how you could use paint and cardboard panels to add final details to make the basic shape look cooler



12 volt car battery adapter



low watt party bulbs

[IconBasser]

ah, trolling the neighbors, are we?

[stevetx19]

Originally Posted by IconBasser

ah, trolling the neighbors, are we?

you have no idea....

[stevetx19]

Originally Posted by BogeyBass

This is a real cheesy drawing....not to any scale

But i was thinking of a flat profile where you can get as many pieces out of a single piece of material.

So using cardboard or possibly 5mm luan plywood used for flooring substrate and build a frame.

Then maybe use cheap painters drop cloths to stretch and staple over the frame.... and then paint and add details with paint.

as far as lighting maybe somebody already has a low wattage 12volt dc adapter so you can plug.....110volt ac 4 watt florescent party bulbs to a car battery.



here is just a basic idea how you could use paint and cardboard panels to add final details to make the basic shape look cooler



12 volt car battery adapter



low watt party bulbs

Amazing, thanks! Right now i'm thinking something like this as well. My concern is that the weight of the pieces might be too much, and the ring would sag. I think if i made it out of Styrofoam this would be avoided. It would provide more depth than cardboard, at least, and be quicker and stronger than paper mache.

[UncleFluffy]

Originally Posted by kingpin2512

Chicken wire or something similar with paper outside that you use a sharpie to color?

Chicken wire form, papier-mâché outer shell (you can do it with old newspaper and flour-and-water paste if you're really on a low budget), rattle-can paintjob.