The only part of putting this kit together that is not straightforward has to do with the detail plates and the faces of the various modules they get applied to. I'd like to begin with an explanation of what you may, or may not, have in your kit.
The module groups that make up the spine of the Discovery are made of only 5 different designs, plus the module that the Antenna Array sits on. All the designs (except the Antenna Module) are identical in shape, but differ in length. So, I've dubbed the 5 different modules A through E. The A module is the longest. The other modules are used in pairs and the length of each pair equals the length of the A module. So, these 4 modules are the C/D pair and the B/E pair. The A module is not used in the Antenna Array grouping. The E module is cast as a solid piece, so it won't be discussed in this section.
The modules used in this kit were made for the Large Discovery model, in certain cases they were made years ago. Their age is not important, but exactly how they were made effects what is actually in this kit. The main difference is that some modules were cast with the outer face open and the newer ones have been cast with an end open. In either case, this was done because the modules could not be cast solid, they had to be hollow. To finish either version, the open side or end has to be closed. This is done by pouring resin into the module casting and letting the resin cure against a piece of plexiglass.
NOTE: All of this information is provided only so that you understand what wound up in your kit. All module ends/faces come to you already sealed. You only have to apply the detail plates!
The following series of photos takes you through the casting of the B module and sealing the open end--
This is the mold and its core. Resin is poured into the mold such that when the core is set into it an amount of resin overflows, (hopefully) taking all the bubbles out with it.
Some of the time, this does not work! So--
The bubbles are taken out by a dremel tool and abrasive disk. It is important to get all the bubbles, but not disturb the outer edge.
A bit of resin is poured into the module, which is capped with a piece of plexi, inverted and set on the table until the resin cures.
Here you can see the sealed end, on the right. The other module was capped in a different way.
One of the B module molds was no longer usable, except for the end. So, the end of the mold was cut off and used in the same way as the plexiglass, only in this case the end detailing was also cast in place. This worked well, but was dropped in favor of the plain, sealed end.
Here you see the B module (on the right) and the C and D modules. The kit now includes a selection of detail parts that can be applied as you see on the B module or on the C module, on the left. The D module, in the middle, has a different arrangement. Both the C and D modules have their end detailing molded in place, but the detail parts provided can make either the B or C style of end. It is important to note that exactly what is on the ends is not important--
As you can see here, when these ends face each other, you can't really tell what is stuck on the ends-- just like in the movie! So, how these ends look is totally up to the builder.
This is the D module. All D modules used in this kit are cast with the outer side open. It is sealed in the same way the end of the B module is sealed.
Both the C and D module are made the same way, so this outer side needs to have detail plates stuck on. I provide a number of different plates that can be used on both modules. Some fit as they have been cast, others need to be modified, as seen on the left, so they fit properly. Again, exactly what is on this face of each module is not set in stone. This is where the builder can personalize his model, bringing his own creativity to the project by using what is provided or coming up with something else on his own.
Some kits even include B modules that are complete, with the end and outer face finished. As I said in the beginning, a lot of modules were cast up for the Large Discovery models and that's what we use in the kit. Which version of the module is the only real question, but the kit includes enough extra parts to make finishing the model as painless as possible!
Also, some kits will have the dish base cast as one part (on the right) or it will be in two parts. I had to make a new mold of this part, so I elected to reconfigure the master into two pieces, which makes casting this part much easier!
