White Dalek Costume DIY

How to Build or make a DIY Dalek Comic Con Halloween Costume for a child or an Adult. This build of a Dalek Halloween Comic Con costume is made out of inexpensive supplies such as, PVC pipe, styrofoam, a laundry basket, plastic carry all and a plastic mixing bowl, balls cut in halves, cheap solar light, duct tape, high temp glue, and stuff just laying around the house /garage.
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White Dalek Costume DIY

How to Build or make a DIY Dalek Comic Con Halloween Costume
for a child or an Adult. This build of a Dalek Halloween Comic Con costume is made out of inexpensive supplies such as, PVC pipe, styrofoam, a laundry basket, plastic carry all and a plastic mixing bowl, balls cut in halves, cheap solar light, duct tape, high temp glue, and stuff just laying around the house /garage.
dalek plans pattern
dimensions white dalek
This pattern is readily available on the web. These dimensions are for an adult size dalek. We scaled them down for a child.
Video of how we used a heat gun to bend the PVC for the Dalek frame.
Transfer the dimensions to a piece of wood and use screws at the corners to create a jig for bending the PVC
dalek design bottom 2
Use Duct tape to hold the sections as you move around the jig
Cut the PVC and install Ts to use for the verticle supports for the Dalek bottom
The bottom with all T's installed
dalek design bottom 1
dalek design bottom 3

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diy dalek 1
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Dalek frame top and bottom connected and ready to use pipe adhesive
Draw around the bottom of the black tub onto a board and cut out . Fasten to the PVC with Duct tape .
This is a solid 'tub' of sorts w/ handles removed.  Insert a section of a tomato cage to shape as needed.
diy dalek 4
diy dalek 5
Attach small angle brackets to board and fasten black tub to all brackets. I used a pop riveter but, nuts and bolts will work.
Inside look at black tub with hole cut in bottom and painted white then fastened to board on PVC dalek frame
The "Skeleton" of the Dalek - black tub, cheap laundry basket, & clear mixing bowl.
diy dalek frame
diy dalek frame 1
diy dalek frame 3
Measure, cut and fasten styrofoam sheets w/ duct tape
Continue, duct tape outside angles w/ white duct tape
Done
diy dalek frame 4
diy dalek frame 5
diy dalek frame 6
Black foam pipe insulation fitted for bottom bumper - perfect.
Used white duct tape over styrofoam because we found out that the plastic paint melts certain styrofoam - oops.  Note that we cut some sections out of the laundry basket
Sensor: Bottom of 2 liter bottle, 3/4" hole in bottom for pvc pipe, 1/2 of a 3 1/8" ball (any size would work), painted gold
diy dalek accessories
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Another angle shows PVC hot glued in 3/4" hole
Plastic souffle cups painted gold.  It only takes 2, but we painted 3 - oh, well, you can't have too many ears
Basket & mixing bowl painted white w/ spike of cheap solar light installed, small painted foam pc for aesthetics
diy dalek accessories 3
diy dalek accessories 4
diy dalek accessories 5
Solar light top and cups painted.  The blue "light" is a magic sizing lid cut down
Styrofoam rings added to eye stem.  2 big & 2 small.  Size is whatever looks good to you.  Solar spike used for perfect center cut.  Inside screen started.
Hot glue balls to Dalek after dry fitting w/ duct tape. Level the 1st row then measured about 3.5" between balls.  Important to "eyeball" dry fit before gluing.
white dalek body
white dalek body 1
white dalek body 2
Dalek's balls are done.  Now on to the weapons and bars.
The gold bars are just painted styrofoam (whatever size looks good to you).  The "weapons" are inserted through lunch meat containers painted white with foam inside then pop riveted to the tub then caulked for aesthetics.
The machine gun is a gold painted paint roller frame with handle straightened & shortened then black plastic flexible wire conduit slipped over the spines of the roller frame then painted gold.  Cat is optional.
white dalek body 3
white dalek body 5
white dalek body 6
Close up of rings on the "eye".  Nnote the bar is bar for the eye is balanced between small space bowl and basket, but hot glued as well for added stability
The screen inside laundry basket is black gutter screen painted gold then cut in wedge shapes to fit in between supports on launddry basket with hot glue
A styrofoam "belt", center pc, and gold ring at base of sensor were added for aesthetics.  You can see here how the lunch meat tubs look close up when finished.  The rivets were painted over with craft paint so you cant see those.
Comparison between home made Dalek and a real Dalek.
Time spent on construction: about 48-50 hours
Materials bought: about $200
Grandparent bragging rights: Epic !
Memories with grandson: Priceless !
diy dalek 6
Our Grandson tries the Dalek costume out for the first time!
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