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I used acid-etched stencils to achieve the ENTERPRISE markings. (For an in-depth explanation of the acid-etching technique, by
one of America's top Model Builder's, I refer you to the piece on acid-etching at the CultTVman site). I first drafted out... you know, that arcane and oh so primitive craft of maneuvering pen and
drafting tools over a bleached piece of parchment, connecting the dots with lines and curves... the artwork two times the required size and had it reduced, as a sandwich transparency, to actual size in a
process camera.
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I spray painted the appropriate colors through homemade acid-etched stencils. Here you see the 'NCC-1701' markings stencil near
the painted character that has just been laid down with the spray-brush. To prevent 'under-spray' from running under the edge of the stencil cutouts I took care to make the paint as thick as possible and
to project it against the work with the minimum of air-pressure. A double action spray-brush was the way to go here.
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Plotting the correct position of each marking is, of course, a vital task. Note that here I'm using adjoining masking tape
guides to assure correct placement of the stencil before spray-brushing in the paint. Note a 'forked' Popsicle stick used to help me press the thin brass acid-etched painting stencil into direct contact
with the models surface - this to prevent under-spray.
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The completed 'USS ENTERPRISE' and 'NCC-1701' markings atop the Primary hull of my twenty-nine inch long scratch-built
ENTERPRISE model. Waterslide decals require a gloss type surface to snuggle down onto and dry-transfers this size are very hard to manage, and a custom set would have been prohibitively expensive.
Traditional tape masking, chart-pack, or use of self-adhesive films would have been a viable alternatives as masking agents, but each presented its own set of conformal and adhesion challenges.
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There are always many different ways to skin a cat. The trick is choosing the best method of the choices available. The Skilled
Model Builder has many choices available to him.
Strips of masking tape was sufficient to boarder the outlines (inside and out) of the many 'technical' markings that adorn the ENTERPRISE model.
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The numerical 'frame numbers' and hash marks on the side of the Secondary hull were characters spray-brushed through acid-etched
stencils. The horizontal red bars of the StarFleet logo were masked off with strips of tape and painted. The yellow boomerang thingy was painted through an acid-etched stencil.
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Long before the final colors went down all lighting had been tested, installed, tested again, and all cable runs checked for
free running and non-interference with sub-assembly union. Here the painted portions of the model are being fit together as the lighting wires are pulled into the Secondary hull, made up to the internal
buss and then routed down out through the hole that will later mate with the Support Stand.
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Positioned for final gluing the starboard Warp Engine Pylon is pulled erect with a piece of masking tape. A special assembly jig
was made and used to assure correct alignment of the sub-assemblies as they were permanently bonded together.
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Nearing completion. Here I'm pulling the Warp Engine ribbon wire and control panel wiring out the front of the open Secondary
Hull. Out in the open a 'floating' buss terminal is used to make the connects between panel and LED wiring. Use of hemostats to fish out and hold wires within the model was a necessity. Note that the
Support Stand is a semi-flexible hollow tube that can be bent to position the model at just about any attitude desired.
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The Hangar Bay was installed and the LED's mounted within the Secondary Hull used to backlight the hangar overhead and control
stations. Once happy that all was in order the seam between the Secondary Hull and Hangar Bay piece was filled with two-part automotive filler. Then the seam was finished off with touch-up putty and
sandpaper, primed, and then painted. The plastic sheet working mask, described earlier, was used to protect the finished Hangar Bay from these operations.
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After epoxy'ing the two Warp Engine pylons into the Secondary Hull slots, the gapes were filled, worked with file and sandpaper
and finally primed and touch-up color paint applied to hid the work.
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Finally, the Primary Hull was positioned over the Seconday Hull Dorsal piece and, employing the alignment jig, epoxied these
sub-assemblies in place - this done only after running all Primary Hull wiring down into the Secondary hull, hooking the wires up to the buss, and conduction a full-up systems test. Note the use of soft
foam pads to support the model assemblies - all parts have been painted and markings applied.
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All that remained was the touch-up work at assembly union points, weathering and the final clear coat. Didn't want to scare the
finish on a nasty old workbench at this point!
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The nearly completed ENTERPRISE model mounted vertically to permit easy application of 'streaking' weathering to the leading
edge of the Primary Hull with spray-brush. Note to the right, just hanging off the edge of the table, the wire connector leading from the lower end of the Support Stand. This will eventually mate to a
receptacle within the Display Cabinet and down to the control panel.
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The lit twenty-nine inch vacuformed and cast resin ENTERPRISE model ready for display. Nothing to it!
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