Making Moulds

There is only one material to make Daleks from, Fiberglass. It's light, tough and can make any shape. It also allows you to produce multiple copies easily if you construct a Mould to form it. However, it's  extremely unpleasant to work with and you must ensure you follow all the safety precautions advised. The skirt, shoulders and head were produced in fiberglass.

The first step for each of these was to produce a wooden former from which a fiberglass Mould could be taken. This Mould would then be used to produce the finished fiberglass shell.

As the wood would be destroyed after the Mould was completed it was only necessary to use off cuts with rough construction techniques.  Only the surface finish was important.