ALANOODLE'S SCALE MODEL PORTFOLIO

Building Lunar Models'
DISCOVERY
from
2OO1: A SPACE ODYSSEY

Discovery
Drawing modified from Shane Johnson's U.S.S. Discovery Blueprints

Tutorial by Alan Nadel
This tutorial in a slightly different form originally appeared on the 2OO1: A Space Odyssey Collectibles Exhibit



 
    I've been a big fan of the film 2OO1: A SPACE ODYSSEY since I first saw it in 1969 at the age of 13. I was a little too young at the time to appreciate the gist of the film but it kept me coming back to see it again and again over the years. 2OO1 also changed forever the way we view sci-fi "hardware" which until then, still seemed influenced by the Buck Rogers serials of the 1930s.
   As a sci-fi fan and an avid modeler, I was thrilled when Aurora and Airfix released kits of the Orion Clipper and the Moon Bus although I was disappointed that no other kits from the film were produced, especially my favorite spacecraft, Discovery. It took about twenty years for Discovery to be produced by "garage kit" manufacturers, home hobbyists who make their own molds and cast kit parts by hand. Of the kits that I knew that were available in the early 1990s, the best and most readily available was made by Lunar Models.

  The kit came in a heavy corrugated cardboard box with a label and photograph of a finished, painted kit. Larger parts were in their own separate bags, smaller parts separated into two smaller bags and one bag contained the fuel pods which would be lined up along the ship's spine. The 3 long spine parts were wedged into the box diagonally, un-bagged.

    This was not my first experience building a kit by Lunar Models. As is common with their kits, the quality of the parts was inconsistent. While some parts were expertly cast with sharp details and few air bubbles, others were of a quality that would no doubt cause them to be considered unacceptable by another garage kit maker. It required a little creativity to get some of the parts to a usable condition. It took a little more creativity to scratch-build others.
Open Door    Lunar Models' Discovery spacecraft is an intimidating kit. It includes 84 resin parts, many of which are cast poorly. Most of the parts would need a lot of work and some would be replaced with scratch-built duplicates. (As is often the case with anything hand-made, and garage kits are no exception, consistency of quality can be tough to obtain.)

   The spherical "Command Section" had its problems. The middle of the three pod-bay doors showed signs of some serious mold deterioration. There were some resin lumps and berries that were so bad that it became necessary to grind out the entire door with a Dremel rotary tool.

   Fortunately, the kit came with an extra bay door to build the kit with the pod-bay open. I used it to replace the removed door. A hold-down jig was made for the sphere to make it easier to mill a flat seat for the new door. The 3/8 inch thick resin of the part was milled to just under 1/8 inch and the new door was glued into place.

   Overall, detail looked klunky and a little exaggerated with many air bubbles in the resin. Some panel lines were at slight angles and others almost looked as if they were scribed freehand. Most of the detail was filled with putty and sanded smooth until the part was nearly featureless. Instead of scratch-building the lost detail back onto the sphere, I decided it would be added back to the model as painted-on features.

Inside Sphere
New door
   The hollow pressure sphere was sanded on the inside until Discovery's sealed front window was open. The Command Room was scratch-built with sheet styrene and model railroad bulbs. A video tape of 2OO1 was used as a reference as was Shane Johnson's "Discovery Blueprints" which have excellent diagrams of the spaceship's interior. Assorted decals of instrumentation from other kits covered the back wall. The Command Room would be visible through the narrow slot of the front window so details were kept to a minimum. Three 3-volt model railroad lamps light the interior space - two in the lower corners, one above the center corridor. The photo on the right shows the finished Command Room with a nickel for scale. Discovery interior
    As cast, the Command Section has eight of what are labeled in the blueprints as "reaction control thrusters." The Discovery in the film had only one of these thrusters (visible just below and behind the pod-bay door in the drawings below). I filled in the other seven with Squadron brand filler putty. The air-lock door on the port side of the pressure sphere was way too deep and looked more like a trench than a door. It was also filled with putty. When the putty was cured it was wet sanded until flush with the curve of the sphere. Cured Squadron putty expands when it gets wet and shrinks when it dries. The putty on the air-lock door shrunk just enough to give it a better, more subtle recess.

    Probably the most obvious problem with the Command Section was that the part was short by 1/8 inch which caused a mismatch between the sphere and the flange behind it. A spacer made from 1/8 inch thick sheet styrene was glued to the back of the sphere which corrected this problem.

Offset Spacer
    The conical section behind the Command Section was replaced with a section of a styrene Estes Rocket nose cone detailed with a one-half ounce half-and-half container like the kind served in restaurants. This improved on the accuracy of the part. The part was then drilled out and a piece of 1/8-inch K&S brass tubing was glued inside to reinforce the joint between the flange and the spine.
Un-modified flange Nose cone
Got milk? modified flange
    The three section, 20-inch long spine is made of resin cleverly cast over brass for strength. The two ends are cast over brass rod and the center section over brass tube, making for a secure fit as well as providing locator pins for the Command Section in the front and "Reactor Section" in the rear. The spine of my kit was fairly straight and cast pretty well but I have heard that owners of later kits weren't so lucky.
    The spine was nicely molded with lots of fine detail. One of these details, the spine "Segment Clamps" (arrow, right), run along the spine in 36 places. Many were broken and were replaced with pieces scratch-built from sheet styrene.

  Click here to view the instructions that came with the kit. (Adobe Acrobat Reader required.)

   Lunar's instruction sheet has a diagram showing the locations of the 62 fuel pods which come in three sizes and are positioned along the spine.  Though confusing at first glance, the instructions were helpful in arranging the fuel pods in their accurate configuration. In order to ensure that all the pods wouldn't look uneven when glued to the spine, a jig was made to hold each one down on a milling table and they were all milled to the same thickness. When glued to the spine, the pods lined up fairly straight.

Spine
    The entire communication antenna and mounting were unusable. The base was modeled after the Discovery in 2010 and the antenna mast was not only warped but short cast. The three dishes were anything but dish-shaped and the main antenna's probe was so covered with flash and resin lumps that it took me a while to figure out what it was. New dishes were made from sections of spherical fuel tanks from another kit and a new swiveling mast and base were scratch-built from sheet styrene and acrylic rod. A new probe for the main dish was made by chucking a piece of 1/16 inch acrylic rod in a hand drill and shaping it lathe-style with a needle file. Dish cross members were made from strips of .020 inch sheet styrene.
Reactor Section    The Reactor Section was detailed using a combination of K&S brass wire with spare parts from other kits. 1/8-inch diameter holes were drilled in the front and back ends of the part and a length of brass tube was glued inside the piece flush with the front and extending 3/8 inch from the back (indicated by the gray stripe in the photo at left). This would help to secure the joint between the reactor and the back end of the spine and would also provide a locator pin for the center engine.

   This hollow cast part was almost problem free with an easily cleaned up mold parting line. One of the three engines looked as if it were cast during another run of the kit. While two of them were cast in light tan resin with very sharp detailing, the third was a darker (maybe older?) resin with very soft details. These details were sharpened with a Dremel and the addition of sheet styrene.

   The EVA pod is beautifully detailed for its size, about 5/8 inch high. Though not entirely accurate, I thought it looked good enough to leave alone. It comes with a pair of very delicate 5/16-inch long resin arms which, after flash removal show a lot of detail and really look good for the scale. The "WARNING: EXPLOSIVE BOLTS" marking on the door (which may or may not actually say that - it's too tiny to read) is from a 1/72 aircraft kit. EVA Pod
    The model was painted with Tamiya acrylics. Using my trusty Badger 150 airbrush and lots of masking material, I painted a complex series of panels, stripes and markings on the Command Section in an attempt to make up for all of the detail sanded off in the process of cleaning up a less than perfect casting job.

    The 32-inch long Discovery was mounted on a scratch-built display stand. The stand's forward support post is topped by a 1/8 inch phone plug which connects to a phone jack below and behind the Command Section and provides the 9 volts necessary to light the Command room. The EVA pod is mounted on a 1/8 inch piece of acrylic rod.

Discovery

    Though I didn't keep a record of my work on this model, I'm sure that with all the part cleanup and additional scratch-building the Discovery took at least 40 hours to complete. Though this kit is considered by many to be one of the more difficult resin model kits to build, I'm satisfied that the amount of work I put into it paid off with a very impressive model. It was impressive enough to win awards in competition and to be sought out to represent the Discovery in a television program on the Discovery Science Channel called Mission Control, 2OO1: A Space Odyssey which chronicles the simultaneous writing of the novel and the screenplay by Arthur C. Clarke and Stanley Kubrick. My experience with the preparation of the model for the show and other fun stuff can be found HERE.

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