DALEK

The 2005 Design Dalek

www.projectdalek.co.uk
 The “2005 Design Dalek” plans by John Darley.

Version 5.3, January 2022

Many thanks to the following people for their

contributions and help during the development of these plans:

James Rossner • Tony Spalding • Phil McNulty • Christopher Smith

Kathy Bergh • Aaron J. Climas • Edward McAndrew • John Surr

This document is subject to copyright.

Unauthorised sale and distribution, in any format, is strictly prohibited.

This document is offered as a free download.

www.projectdalek.co.uk www.projectdalek.com
 ...INTRODUCTION...
he 2005 redesign of the Daleks was a massive success
T which has seen them return to the series on many
more occasions. Their appearance in the new series, in
updated form, captivated viewers and introduced the
Daleks to a whole new generation of fans, many of whom
are now old enough to build Daleks of their own.
Design:
The design brief was simple: to make the Daleks look
solid and brutal. This was achieved by borrowing
elements from the many different Dalek designs of the
past. Design cues from TV Daleks, movie Daleks and
comic strip Daleks all played a part in the creative
process.
The skirt section was based on the classic 1960s design.
This was at the request of showrunner Russell T Davies.
It replaced the more upright look of the Necros, Imperial
and Renegade Daleks which had appeared in the 1980s.
Dalek aficionados will notice that the dome is a
reworked version of those used in the 1980s on the
Imperial Daleks. It has the same sharp chamfer line,
identifiable despite the addition of a new component: the
cowl.
New components which have not been created from
previous references are more difficult to assess.
There is a temptation to try and force all the dimensions
to comply with those set out in classic Dalek plans.
However, the shoulder and neck sections should be
looked upon as entirely new, unrelated parts. If you have
previously studied classic Dalek geometry you will no
doubt question some of the new shapes and their
relationships to one another. Questioning is always a
good thing, but be aware that this is not a classic Dalek.
If you opt to use the classic Dalek dimensions you will
still end up with an acceptable result, but it won’t be an
accurate replica of a 2005 Series Dalek.
For example: compared to classic Daleks the neck rings
are of different diameters and also have unique spacing.
This is not an error in the plans, it is an accurate
representation of the design. I stress this point here
because experienced classic Dalek builders may feel
slightly perturbed at being moved out of their comfort
zone. If you are new to Dalek designs, taking the plans
on face value is the best policy.
Plans development:
The first version of the plans was developed using
photographic references. Known sizes were used to
extrapolate sizes for other parts. The work was long and
hard and included a good degree of educated
guesswork. By version 2, most of the guesswork had
been either verified or amended using measurements
taken from genuine props.
One important development was that the origins of the
original skirt sections used by the BBC came to light.
This allowed the dimensions to be verified using
measurements taken from skirts pulled from the exact
3
same moulds. The skirt section presented here is a
‘cleaned up’ version of the original, removing a small
degree of asymmetry from the design. This has been
done because, given the choice, most people prefer a
symmetrical skirt to a wonky one.
With the release of version 3, a considerable number of
measurements had been independently verified by
reliable sources with access to the props. Much of this
information related to the gun box assembly and neck
section. Many of the previously published dimensions
were found to be spot on or within a few millimetres.
The version 4 release followed, with corrections and
adjustments. By now, very few of the revised
measurements were solely the result of extrapolation.
A notable exception to this remains in the plans you are
reading now: the cutting claw. This is still under review
and some small changes may appear in future versions of
this booklet.
Version 5:
In this revision, the gun and eyestalk layouts have been
further expanded to include even more information.
There is also much more detail on the plunger, which has
been reworked, along with the eyeball, to match the
EMA (Model Supplies) component dimensions used on
the original Dalek seen in the episode ‘Dalek’, rather than
3D printed versions that followed on later props. EMA
part numbers have also been included for those who
wish to use them.
Version 5 also sees minor adjustments to a number of
other dimensions, to hone accuracy and iron out small
bugs.
Variations:
This Dalek variant has become known as the ‘New
Series Dalek’ or just the NSD. I have avoided using that
name here so that it is clear that the plans reflect the
design from 2005. To cover the minor changes to the
design that have happened since then, alternative
dimensions have been added where required.
Units of measurement:
The measurements in these plans are presented in
millimetres unless otherwise indicated. Occasionally
component sizes make more sense in imperial
measurements. Where this is the case, the sizes are also
given in inches (in red) below the metric measurements.
All imperial measurements are highlighted in red.
Caveat:
These plans are the product of many hours of hard
work and edge close to being a final and definitive
documentation of the 2005 Dalek design. However, as
always, they are subject to change, if and when new
information comes along.
John Darley, June 2018
 ...REFERENCE VIEWS...

Design cues for the 2005 rebuild were taken from a multitude of Dalek sources. There is evidence of the
Peter Cushing films and the TV21 comics in there, as well as the TV series. The domelights and fender belong
firmly in the movies, while the skirt design links us directly back to the very earliest TV appearances.

The Daleks built for ‘The Parting Of The Ways’ had base, skirt and shoulder sections which were cast in
one piece rather than as individual sections.
4
 ...DOME & NECK...
520
460

76
125

85
67
560 OSD 460 ISD
80
580 OSD 480 ISD
87
600 OSD 500 ISD

Rings are 19mm thick 5mm flat edge on Neck rings

The basic design and shape of the Dome (without the etched lines) is identical to that used on the Imperial Daleks.
This Dome variant has a more defined and less rounded chamfer line than that seen on classic Daleks.
Dome & Neck ring dimensions

450
Radius 274 405

250 270

64
500
470 internal frame, 500 including mesh layers
Dome dimensions & details Neck bin dimensions
The Neck mesh is made up from layers of two separate materials. The inner mesh is a standard diamond pattern
wire type, while the outer layer is black anti-slip matting, as used around swimming pools. The initial props used a
matting called Heronrib, but later builds show slightly different markings and rib styles, suggesting that the prop
builders used whatever similar matting was available.
12 6
The Neck section is a complete
rebuild. The chamfered edges of the
Neck rings do not come to a point as
they do on the classic Daleks.
20 They end on a flat edge which adds 240

to the chunky look of the new design.

45º

Strut cut-out dimensions Dome & Neck relationship

5
...DOME DETAILING & NECK BLOCKS...
10 140 115 45º from centre point
All groove measurements follow
10 85 the curvature of the Dome.
120 4
60
3
150
40 2.5
Groove profile
120

50 35
80

45
165 90

Recess depth approximately 0.5mm

60
45 width at
chamfer line
A basic mould was taken from an existing Dalek
50
Dome, then the grooves were created using strips of 70
plastic or rods, glued into place inside the Dome mould.

Further thin pieces of plastic were cut out and used to 50

form the shallow recesses on the Dome front and sides.

Dome detail dimensions

43
20
22 14
12
14 31
4
4
8
31 40

Side view Front view Top view

Note: Block measurements meet at convergence points (the edges are rounded).

The Blocks which adorn the Neck rings were added as part of the design brief which required the Daleks to look tougher.
The first generation of Blocks were made individually, with some versions being 3D printed. Later versions were
attached to the Neck struts, moulded and then recast in polyurethane resin.
Neck Block dimensions

6
 ...COWL...
102
85
40 The Cowl is an entirely new Dalek
32 feature developed for the redesign.
Constructed from fibreglass, this
section was custom made to fit onto
the surface of the Dome.
12
85 The fit is quite loose on many of the
props because the profile of the Dome
and the profile of the Cowl don't
30 match up too well.
30
10 It is possible that a classic Dome was
used as a base when the Cowl was
75 being created, resulting in the slightly
115 different profile shape.
180 (curve 186)
240 (curve 252)
Cowl front view

Note that the Dome is finished in 100 7

the usual deep metallic bronze, 70
but the area behind the Cowl is
painted much darker, possibly
even black in some cases. 2.5

The Cowl is fixed to the Dome

using M6 socket drive, button 120
head bolts. 7
160

Each Dalek has its own individual

I.D. icon painted in the recess 226
under the Eyestalk.
78
You can create your own unique
I.D. by using the font which is
available to download from the
Project Dalek Forum. 12
Cowl side view

7
 ...SHOULDERS...
67 The Shoulder section is a complete rebuild.
It consists of three separate layers. The inner layer
18 30 is a complete skin with the other two layers built
up around it.

A basic plug was constructed from wood, then

various foam materials were used to form the
612
outer two layers. After filling and finishing, this
638
was used to create a master mould for producing
688
the final fibreglass parts.
150 576
The horizontal bands on the original Shoulders are 550
far from even because they were built up using
foam materials and filler. Most of the sharp edges
shown here are, in fact, rounded off, making exact 120
measurement impossible. An acceptable average has 345
been used throughout.

To achieve convincing results, all sharp edges should

be sanded down using photos as reference. 696
722
118 774
77 146

120 All Gun and Arm Box measurements are taken from
53 the Gun Box side and duplicated for the Arm Box.
This is because the two are not absolutely identical.
96
The Gun Box side is straighter, with a better fit and
is used here, as reference for both.
113 120 144

93mm diameter hole

150 13

Later Shoulder castings have more rounded lower 12

collar edges because putty was run into the mould
to help with mould release. 58 90

Boxes inset into lower collar 1 to 2mm

Layer details front and side views

8
 ...SHOULDERS...
774

576 688

Top view Slat positions

A full-sized template of the Shoulder

bottom shape is available to download
from the Project Dalek Forum.

The template also features depth

references for the other layers of material
which make up the Shoulders.

Shoulder/Skirt positioning guide

46 65
156*
13 *Additional length
10 may be required to
145 form a smooth transition
140 114
into the shoulders

13
64

8mm inset depth 156

Angled indentations were added to the sides of the Gun Box. The rounding of the edges is not exact. Filler was used to plug
the gaps and create the internal wall. Dimensions listed here are taken from the (neater) Gun Box side.
Gun and Arm Box side details
9
 ...GUN BOX SURROUND...
138

11

45º
138 10

21

21 11

Layers 1 and 2 combined view

Layer 1 (the square backing section) is 3mm thick. The four triangular holes expose the plain Box front beneath.

132

6.5 94

Layer 1 diameters

10
 ...GUN BOX SURROUND...
Layer 2 (the circular section) is also 3mm thick and contains matching bolt holes to those seen on Layer 1.
137

137 114

25º

Layer 2 dimensions

This detailing surrounds the ball joints and is fixed into position on the Box fronts using M6 socket drive,
button head bolts. These were fitted through the bolt holes featured in the design.

8 4

Layer 1 corner curve dimensions

11
...GUN BOX SURROUND TEMPLATE...

This is a representation of the detail around the Gun and Arm Box portals. Please feel free to use it as a template.
Its two layers create a raised relief that is screwed into position on the Box fronts.

Just about every corner is rounded. The originals were produced using fast-cast resin poured into shallow moulds.
Roughly finished, they can often be seen curling slightly at the edges.

1:1 template view

12
 ...SLATS...
The basic thin Slats which have adorned Daleks since the 1960s have been replaced by much heavier versions.
Designer Ed Thomas and concept designer Matt Savage wanted the Daleks to have a much tougher, heavier appearance.
152 62 62

40

130
x1 x4 x13

235

120 30
Holes for bolt heads or round covers: 19.2mm diameter.
Bolt heads or domed covers: 14mm to 19mm.

Top profile of large Slat showing the curved profile to fit Shoulder shape. 30
Front view

16 16
4
Few Slats are absolutely identical because the moulding process
4
produced distortions. The rear insets were subject to minor
44
20 20 modifications in order to achieve a good fit.
44

13 * 13 * The most radical modification is to the front-most long Slats

which attach at either side of the Gun & Arm Boxes.
78 53 These have part of the lower side section cut away to
accommodate the change in collar depth, near the Box sides.
120 20
Modification is also necessary in order to get the Slats to fit well
8
3 against the curve of the Shoulders. The bolt heads holding the
16
Slats in position are counterbored into the Slat surface.
29
* Cutout depth on all slats 12mm,
Some later props used self tapping screws, masked by plastic
12
tapering to 0mm at the bottom. covers.
46 Hole depth and the diameters of the domed heads often varies from prop to prop.
20 Screws were never used on the props which housed Dalek operators due to the risk of
3 injury from the protruding screw tips.
16 Side view
29
13
 ...SKIRT...
714
The Skirt section is very 259 338 280
much a 1960s design. 96 94
This was an intentional 180

decision, made because the 40

production team didn't feel
that the more upright 80s
skirts were appropriate.
315
259
142 178

178
230
320
380

102

317.5
533 440
1067
Skirt upper & lower detail

154

686
27” 154

154
45
103

144 90

121 105

For more details on the Fender, refer to the Fender Base section within this booklet.
Skirt & Fender side view
14
 ...HEMISPHERES...
Because the two skirts used on the first 2005 Daleks were donor sections, taken from classic Daleks, the
Hemispheres were slightly shallower than those on later props. Details for both versions are included here.
2.5 48.3

104 110 101.6

4”

12
Each of the 56 Hemispheres is framed by a black ring. These rings are actually based on an off-the-shelf
automotive part. They are casts taken from a rotary shaft oil seal, as used on certain DAF heavy goods vehicles.

Early style Hemisphere & surround

Later Hemisphere surrounds were made by producing a mould from an original oil seal. This was then used to
make copies in fast-cast poyurethane resin. Because this type of resin shrinks as it cures, the dimensions of
recast surrounds may vary slightly from those shown below. Recasts were often pink or beige-yellow in colour
and were painted black prior to being fitted. 2.5 50.8
2”

104 110 101.6

4”

12
Both versions of the Hemispheres were attached to the fibreglass Skirts using bolts, rather than inserted
through 56 large holes, as they were on the classic Daleks.
Later style Hemisphere & surround
15
 ...SKIRT PANELS...
276 327 268
147 11 182 4 168
1.5

722 700 692

205 258 224

Panel 1 (front) Panel 2 Panel 3

A small degree of asymmetry is evident in the genuine Dalek Skirt Panels. Therefore, the
corresponding Panels on the left and right sides do not match exactly. This has been corrected here
giving even Panels which stand up better to close scrutiny.
64 280 4 167 6 52 356
1

689 696 692

440 177 460

Panel 4 Panel 5 Panel 6

16
 ...HEMISPHERE POSITIONS...
The measurements presented here represent the relative distances marked out on the flat Panels,
not the vertical distance from the Base, such as on an assembled Skirt where the Panels slope.
74 91 84

164 159 156

164 159 156

164 159 156

110 107 105

103 132 111

Panel 1 (front) Panel 2 Panel 3

The 2005 Series Dalek does not have a significant Shoulder/Skirt overlap, making the gap between the upper
Hemispheres and the lower Shoulder collar appear larger than on most classic Daleks. The positions given here are from
the original source Skirt that was used to build the first Dalek. However, Hemisphere positioning is part of the final
look, and it is up to the builder to study photos and adjust to the look and feel that they prefer.
76 76 84 76 76

153 154 154

153 154 154

153 154 154

103 104 103

90
Panel 4 Panel 5 Panel 6

17
 ...FENDER BASE...
Horizontal top section

193

440
375
220
This area is hidden under the skirt.
Cut out central hole as required.
Sloping section

8
126

361
Fender bolt positions
594 481

1196 45
Horizontal perimeter, where the sloping section begins

Horizontal top section

225

485
417

251

Sloping section

144

394
640 512 45
1293
The surface of the Fender is quite rough and deliberately stippled in order to give it a heavy duty look.
The Fender ‘bolts’ are actually M4 socket head, cap screws. A total of 44 are required.
Vertical outer edge, where the sloping section ends
18
 ...FENDER PANELS...
This page shows only the flat shapes of the Fender Panels. Additional engineering drawings of the Fender Base
(which include cut angles for the sides of the Panels) are available to download from the Project Dalek Forum.
25.8 10.7 10.7 7.1
253.8 281.8

70.3 Sloping section 70.3 Sloping section

90 Vertical section 90 Vertical section

290.3 299.6
Panel 1 (Front) Panel 2

The Panel dimensions follow the same layout as the Skirt Panel pages, starting with the front most Panel and
working back along the Dalek. Flip the Panels for the opposite side.
7.1 6.1 6.1 25
241.3 481.4

70.3 Sloping section 70.3 Sloping section

90 Vertical section 90 Vertical section

254.5 512.5
Panel 3 Panel 4
The edges of the Fender Panels (where they join together) will need to be angled in order to achieve a good fit.
The angled cut details are not given here because construction materials and thicknesses will vary. If you plan to use
18mm MDF, the engineering drawings (mentioned above) contain the information required.
25 12.9 12.9 12.9
227.4 494.6

70.3 Sloping section 70.3 Sloping section

90 Vertical section 90 Vertical section

265.3 520.4
Panel 5 Panel 6 (Rear)
19
 ...DOMELIGHTS...
The new style Domelights consist of a pair of
custom made cages surrounding a polycarbonate
lens, manufactured by a company called Moflash.
The ping-pong-ball style light bulbs (not shown)
are a deliberate reference to the original TV
Daleks. The bulbs are round, pearlised BA15D
style units with bayonet fittings. Being 12v
24w, they are commonly used in garage
inspection lamps.
Side view Top view

*
The depth of the lower ring can vary. 84 12
Earlier props appear to have slightly 52 7
0.2
shallower versions. Adjust to change the 5
amount of exposed Moflash lens top.
61
49
46
Fixing holes
75 75

22

6 0.3
2
*
12-15 14 6
5
75
Upper ring top and side views Lower ring top view & cross section Struts (x4) side & front views

48.5 3.4
71.7
8.3
51

73 101.6
4” Internal
46.6 grooves: x40
0.5

13.3
7 4
51
71.7 Wall thickness 2.2 Corner radius 3mm
Moflash lens side view Moflash lens underside view Moflash lens detail
20
 ...EYEBALL...
VT-375
The original Eyeball was made VC-90
Vessel tubing
almost entirely from parts supplied 90° vessel cone
by EMA Model Supplies. Lens
(Not EMA)

The part numbers are given here

for those that wish to order the VHH-400
components from EMA. Hemispherical head

www.ema-models.co.uk VT-400
Vessel tubing

MRH-160P
12 required (3x packs of 5)

EMA parts isometric breakdown

100
10 25 50
Note that VC-90 is a single vessel
cone, cut into two pieces, with the
smaller section turned 180° to fit
inside the larger section.
95.25 76.2 44.45
3.75” 3” 1.75”
Later versions of the Eyeball were
3D printed in two sections, rather
than assembled from many parts.
Radius
15 50.8
All steps = 3.175 2”
0.125” (1/8”) 40
Cross-sectional view

M3x8 socket
cap head screw (x3)

101.6 44 101.6 54
4” 4”

4
Standard iris Mechanical iris
21
 ...EYESTALK...
15 38 15

25.4

30 15 15 140
3.175
0.125” (1/8”)

Components breakdown version 1

Like the Eyeball, the eye HD-300

discs were made from EMA catalogue numbers are included here.
HD-350
components sourced from
EMA Model Supplies.

For those who wish to

scratch build the eye discs,
the details are given below. HD-400

Assembled parts version 1

82.5
73
63.5

23 76.2 23 88.9 23 101.6

3” 3.5” 4”

13.1
15.1
17.1
HD-300 HD-350 HD-400

Disc details
22
 ...EYESTALK...
30 15 38 15

25.4

15 15 15 140
3.175
0.125” (1/8”)

Components breakdown version 2

The Eyestalk components are HD-300

assembled onto an inner tube
which runs from the Eyeball
(from the black collar section)
through to the pivot.
Each disc and section of tubing is slid over
the central tube (not illustrated), creating
HD-350
the illusion of a single, continuous outer tube.

22mm diameter, copper

plumbing pipe is usually ideal
for the hidden, central tube. HD-400

Assembled parts version 2

36 97
The grooves on the edge of
the eye pivot were originally
created by cutting shallow
slots into the pivot surface.

100 22.2
On later props this feature is
created by the use of a ribbed
rubber strip, glued to the
6.3 curved pivot edge.

1.5 width x 1.0 depth

Pivot details
23
 ...GUN...
10 30 235 48 To 202 (recommended)

100

45º 210 45º

25 25 The Gun is a custom made
unit put together from
Length of straight rod = 260 machined aluminium parts.
4.76
0.1875” (3/16”)

Side view

30
8 11 11 3
3 6 13.5
1
45º

43 40 34 26 39 41 25.4 33.5 *

5
5 *Pitch circle diameter
2.5 2.5
Front boss side view Front boss cross-sectional view

43 25.4 43 25.4

Front boss front view Front boss rear view

24
 ...GUN...
Tapped holes drilled completely through the boss. These are used to fix
the boss in position using a grub screw (M5). These fixings are
normally positioned to the underside of the Gun.

Front boss isometric rear view Rear boss isometric front view

48
10 11 15 10 5
1
45º

58 44 42 26 58 60 33.5* 25.4 50
3

*Pitch circle diameter 5

Rear boss side view Rear boss cross-sectional view

60 25.4 50 25.4

The rear is drilled out to accommodate the curvature of the ball joint.
Rear boss front view Rear boss rear view
25
 ...PLUNGER...
VT-32
The Plunger is another component made from Vessel tubing
parts sourced from EMA Model Supplies. VX-225
Ring flange

VHH-450
Hemispherical head

VHH-400
Hemispherical head

VHD-475
Dished head (rim) VX-40
Ring flange
(2 required)

KW-12
Column wedge
(4 required)

VX-200
Ring flange
VHH-425
Hemispherical head EMA part numbers are given here for those
who wish to reproduce the Plunger using
parts from www.ema-models.co.uk

EMA parts isometric breakdown

Dimensions are also given on the Subsequent versions of the Plunger were
following pages for those who wish produced by the 3D printing process also
to build the Plunger from scratch. used on parts of the Eyeball, Domelights
and Neck section.

The 3D printed versions were cheap to

produce and quite durable. However, they
required a good degree of filling and finishing
in order to make them presentable.

Fine print lines are sometimes noticeable on

some components.

EMA parts assembled sections isometric view

26
 ...PLUNGER...
45 Note: wall thickness of all pieces = 3.2mm.
35 22

101.6 66 38
4”

14
Inner: Cut from hemisphere VHH-400 (or equivalent)

54

108
4.25”

Centre: VHH-425 (or equivalent)

55
60
44

114.3
4.5” 76 26 32

Outer: Cut from hemisphere VHH-450 (or equivalent)

27
 ...PLUNGER...
120.65
4.75”
114.3
4.5”

108
4.25”
101.6
4”

47

4 8

42

4 8

25.4
1”
31.8
1.25”
Later versions of the Plunger
had additional ribs added to the
39.7
1.5” rear tube.
50.8
2” One theory is that these were
65.1 added to give extra support
2.5” because the Plunger was prone
71.4 to snapping off at this point.
2.8”

Cross-sectional view

28
 ...PLUNGER ARM...

25.4 diameter
1”

25.8
Wall thickness approx 3mm 31.8 diameter
1.25”

32
Wall thickness approx 3mm

395

38 diameter
1.5”

The ball joints were resin casts. The mould

was fitted to the tube and the ball joint cast
up in position. No further fitting or drilling
was required.
100

Plunger Arm details

29
 ...CUTTING CLAW...
18
105 Diameters
14 12
4
4 24

x3
59
x3

25 38

40

17
12
8
For ease of use, the side
profile (above) shows only 45 60 72
16
32
one of the three pincers and
its associated piping.
x3 10
32
22

In reality, three pincers were

10 100
fitted at evenly spaced
intervals around the central
globe (as illustrated here).
30

The Cutting Claw is only seen for a few

seconds on screen in ‘The Parting Of The Ways,’
20 and for much of that time it is obscured by
30 the bright light of the flame.
Cutting Claw details

30
 If you have any comments or suggestions
regarding plans and dimensions for any Dalek type,
please post your feedback on the Project Dalek Forum:
www.projectdalek.com

These plans have been produced for anyone wanting to build a Dalek for their own personal use.
It is not the intention of this guide to encourage any commercial activity regarding the selling of Daleks.

The Dalek name and image © B.B.C./Terry Nation 1963.

Booklet contents © John Darley 2005, 2018.

At the time of writing, the copyright for the licensing and

selling of the full-sized Dalek form is held by This Planet Earth Ltd., Crewe, Cheshire.