This project drew upon some interesting design inspiration.
The result: a novel and interesting outcome.
The result: a novel and interesting outcome.
Design Process
ARROW's Prop master, Ken Hawryliw, grew up watching 1960's television programs. Every once and a while, he likes to sneak in some design references from these shows. This is one of those props.
Prop Master Ken Hawryliw's
Concept Sketch (weapon upper assembly)
Concept Sketch (weapon upper assembly)
Ostensively, the device was a weapon that discharged poisonous gas... and it had to look formidable enough to be a potential "city killer". The final design also had to incorporate the design references Ken wanted. A rough sketch from him (above) was the stepping-off point that lead to the final design, below.
Approved Concept Rendering (major components described)
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The most distinctive feature of the device was the "gas discharge array"
(see "5'"above). This seemingly sophisticated component was actually made from commercially available shower heads. Eight of these were plumbed into a central manifold. In addition, each had been glass beaded to change their original polished-chrome finish to satin. This was principally done to eliminate unwanted reflections that might reveal crew or equipment...
but it also looked good.
The "device display & control electronics" (see "2" above) comprised of reworked components from a previous ARROW prop...
a "C4 bomb" coupled to a type of sensor array (see below).
(see "5'"above). This seemingly sophisticated component was actually made from commercially available shower heads. Eight of these were plumbed into a central manifold. In addition, each had been glass beaded to change their original polished-chrome finish to satin. This was principally done to eliminate unwanted reflections that might reveal crew or equipment...
but it also looked good.
The "device display & control electronics" (see "2" above) comprised of reworked components from a previous ARROW prop...
a "C4 bomb" coupled to a type of sensor array (see below).
"C4 Explosive Device with Human Sensor Trigger & Timer"
This was chosen because it already, possessed a requisite feature... namely, a housing designed to fit a smartphone. Once installed, only the screen of the phone is visible. The Video Graphics Department would then provide a short animation clip that could be played back on the phone screen. This was quite useful, as this could be used to portray any kind of display device. In this instance, it was to serve as a countdown timer for the gas-discharge weapon.
Cosmetically, all that was required, was to change the housing original finish from slate grey to brushed silver. This was accomplished by first, painting the entire housing matte silver and later, the most prominent surfaces were covered with CNC cut, clear anodized, brushed aluminium sheet. This conveyed the impression that the housing was made from cast aluminum...
with some brushed metal surfaces.
Cosmetically, all that was required, was to change the housing original finish from slate grey to brushed silver. This was accomplished by first, painting the entire housing matte silver and later, the most prominent surfaces were covered with CNC cut, clear anodized, brushed aluminium sheet. This conveyed the impression that the housing was made from cast aluminum...
with some brushed metal surfaces.
Countdown Timer Housing
The only real challenge in this assignment, was keeping the weight of the prop to a manageable level. This was because it had to be hand carried up a short flight of stairs, to a rooftop shooting location. To that end, much of the structure originally specified to be 1/4" aluminium plate, was changed to
1/4" acrylic sheet.
To keep the amount of work to a manageable level, (as there were other assignments for ARROW in play) the Prop Department had the ARROW Construction Department provide the these PROPOLOGY designed, sheet metal and plastic components, for later assembly.
While this did make a noticeable weight reduction, the real problem was the eight steel gas cylinders. Although ARROW props had already purchased these cylinders, it was immediately apparent that lightweight duplicates would have to be made (each steel cylinder weighed about 80 pounds!).
A mold was made, of the top aspect of one of the steel cylinders. From this, eight castings were made. These were then attached and blended into lengths of plastic pipe. One painted, they were indistinguishable from the real thing, yet weighed about 8 pounds each. These new cylinders were jobbed-out to another prop building company by the Prop Department, and provided to PROPOLOGY for installation.
1/4" acrylic sheet.
To keep the amount of work to a manageable level, (as there were other assignments for ARROW in play) the Prop Department had the ARROW Construction Department provide the these PROPOLOGY designed, sheet metal and plastic components, for later assembly.
While this did make a noticeable weight reduction, the real problem was the eight steel gas cylinders. Although ARROW props had already purchased these cylinders, it was immediately apparent that lightweight duplicates would have to be made (each steel cylinder weighed about 80 pounds!).
A mold was made, of the top aspect of one of the steel cylinders. From this, eight castings were made. These were then attached and blended into lengths of plastic pipe. One painted, they were indistinguishable from the real thing, yet weighed about 8 pounds each. These new cylinders were jobbed-out to another prop building company by the Prop Department, and provided to PROPOLOGY for installation.
Lightweight, Replica Gas Cylinders & Completed Cylinder Frame
In addition, the entire upper structure had been designed to breakdown into three manageable subassemblies. With these provisions, it was now feasible to transport the prop to the shooting location. Once assembled on set, heavy duty casters; mounted to the base of the cylinder frame, would make it easy to position to camera.
1960's Television Revisited:
Ken Hawryliw's Design Inspiration
Ken's inspiration came from a couple of his favourite TV shows from the '60s: BATMAN and LOST IN SPACE.
The BATMAN TV series from the '60s, featured a myriad of villains... one of which, was the "cold-hearted", Mr. Freeze. The elaborate costume he wore was essentially a life-support system that provided the deep cold, necessary to keep him alive. It featured a distinctive metal collar that was studded with tiny gas outlets that ostensively, surrounded his entire head in a curtain of chilled air. This was Ken's basic inspiration for the "gas-lens ring" feature on the gas-discharge weapon (see "1" above). It consisted of two discs of 1/8" clear acrylic, joined together by a small inner ring and a larger outer ring, both made from 1/4" acrylic. Brushed, CNC-cut, clear-anodized aluminum pieces were added, as well as 16 small gas outlets around the perimeter. These "outlets" were achieved exactly as they were on Mr. Freeze's collar. They were simply metal fasteners known as "pop rivets".
Further inspiration was drawn from the original LOST IN SPACE TV series. This series featured a character known as the "B9 robot" , that appeared in nearly every episode. As an homage to the series, Ken wanted to incorporate a couple of design elements from the robot as well. The first, was the robot's "radar ears" (see above). The "purge valves" (see "3" & "7" above) were modelled after them, but in our case, were represented by a couple of common toilet cutoff valves. They were chosen because the size and shape of the valve knob, closely resembled the "radar ears" of the B9 robot. They just needed to be painted the appropriate colours, and the knobs set to their proper orientations. In addition, the robot's telescopic "bubble support" was mimicked to serve as the gas weapon "telescopic boom" (see "6" above).
Further inspiration was drawn from the original LOST IN SPACE TV series. This series featured a character known as the "B9 robot" , that appeared in nearly every episode. As an homage to the series, Ken wanted to incorporate a couple of design elements from the robot as well. The first, was the robot's "radar ears" (see above). The "purge valves" (see "3" & "7" above) were modelled after them, but in our case, were represented by a couple of common toilet cutoff valves. They were chosen because the size and shape of the valve knob, closely resembled the "radar ears" of the B9 robot. They just needed to be painted the appropriate colours, and the knobs set to their proper orientations. In addition, the robot's telescopic "bubble support" was mimicked to serve as the gas weapon "telescopic boom" (see "6" above).
Fun to design and build. Aggregating design elements from classic television props, with original design, resulted in an interesting and unique new prop.
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