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The Gas Discharge Weapon - For the TV Series ARROW
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This project drew upon some interesting design inspiration—the result: a novel and interesting outcome.
On location, under temporary rain cover.
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 instances.
Prop Master Ken Hawryliw's Concept Sketch (for the 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 seen below.
Approved Concept Rendering (major components described)
1 - "Gas Lens" Ring
2 - Device Display & Control Electronics
3 - Purge Outlet Valve
4 - Gas Cylinder (x5)
5 - Gas Discharge Array
6 - Telescopic Boom
7 - Purge Inlet Valve
8 - Cylinder Connection Manifold
9 - Gas Cylinder Frame
2 - Device Display & Control Electronics
3 - Purge Outlet Valve
4 - Gas Cylinder (x5)
5 - Gas Discharge Array
6 - Telescopic Boom
7 - Purge Inlet Valve
8 - Cylinder Connection Manifold
9 - Gas Cylinder Frame
The most distinctive feature of the device was the "gas discharge array" (see notation-5). 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 and control electronics" (see notation-2) comprised of reworked components from a previous ARROW prop... a "C4 bomb" that was coupled to a type of sensor array (below).
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 and control electronics" (see notation-2) comprised of reworked components from a previous ARROW prop... a "C4 bomb" that was coupled to a type of sensor array (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 housing/smartphone combination was quite useful, as it could be used to portray any kind of display device with any custom readout image required. 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's 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 aluminum sheet. This conveyed the impression, that the housing was made from cast aluminum,
with brushed metal surfaces.
This housing/smartphone combination was quite useful, as it could be used to portray any kind of display device with any custom readout image required. 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's 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 aluminum sheet. This conveyed the impression, that the housing was made from cast aluminum,
with brushed metal surfaces.
The repurposed countdown timer housing with new paint and metal trim applied.
The only real challenge in this assignment, was keeping the weight of the prop to a reasonable 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" aluminum plate was changed to 1/4" acrylic sheet stock.
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 some of the PROPOLOGY designed, sheet metal and plastic components.
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 as each steel cylinder weighed about 80 pounds.
To accomplish this, a mold was made of the top aspect of one of the steel cylinders which featured the needed threaded gas connections. From this, eight castings were made. These were then attached and blended into lengths of plastic pipe that were sized to replicate the height of an actual gas bottle. 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, then brought to PROPOLOGY for installation.
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 some of the PROPOLOGY designed, sheet metal and plastic components.
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 as each steel cylinder weighed about 80 pounds.
To accomplish this, a mold was made of the top aspect of one of the steel cylinders which featured the needed threaded gas connections. From this, eight castings were made. These were then attached and blended into lengths of plastic pipe that were sized to replicate the height of an actual gas bottle. 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, then brought to PROPOLOGY for installation.
Lightweight, Replica Gas Cylinders & Completed Cylinder Frame
In addition, the entire upper structure had been designed to breakdown into three convenient 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 it to camera.
1960's Television Revisited:
Ken Hawryliw's Design Inspiration
Ken's inspiration came from a couple of his favorite 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-ring 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 (notation-1).
Our interpretation consisted of a "sandwich" of two discs of 1/8" clear acrylic. Each was glued atop and below a small inner diameter ring and a larger outer ring that matched the 1/8" disc diameter discs. These were both made from 1/4" acrylic in order to provide a gap between each disc and also make it look a little more substantive.
Brushed, CNC-cut, clear-anodized aluminum trim rings 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 the heads of "pop-rivet" metal fasteners.
Completely assembled, the disc was approximately 5/8" thick. The outside edge of the disc was then sanded smooth and matte silver paint was applied to the surface. This effectively concealed the clear acrylic core of the assembly, visually blending it into the top and bottom aluminum trim rings; making it appear as if the assembly's outer ring was made from a single piece of machined aluminum.
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" on our prop (notations-3 & 7) were modeled 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 colors (matching those of the "robot's radar ears") and the knobs set to their proper orientations to further match the reference's appearance. In addition, the robot's telescopic "bubble support" was also loosely mimicked as the part located between the device's "control and display electronics" and the "gas discharge array" (notation-6).
It featured a distinctive metal collar-ring 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 (notation-1).
Our interpretation consisted of a "sandwich" of two discs of 1/8" clear acrylic. Each was glued atop and below a small inner diameter ring and a larger outer ring that matched the 1/8" disc diameter discs. These were both made from 1/4" acrylic in order to provide a gap between each disc and also make it look a little more substantive.
Brushed, CNC-cut, clear-anodized aluminum trim rings 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 the heads of "pop-rivet" metal fasteners.
Completely assembled, the disc was approximately 5/8" thick. The outside edge of the disc was then sanded smooth and matte silver paint was applied to the surface. This effectively concealed the clear acrylic core of the assembly, visually blending it into the top and bottom aluminum trim rings; making it appear as if the assembly's outer ring was made from a single piece of machined aluminum.
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" on our prop (notations-3 & 7) were modeled 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 colors (matching those of the "robot's radar ears") and the knobs set to their proper orientations to further match the reference's appearance. In addition, the robot's telescopic "bubble support" was also loosely mimicked as the part located between the device's "control and display electronics" and the "gas discharge array" (notation-6).
Fun to design and build. Aggregating design elements from classic television props, with an original design, resulted in an interesting and unique new prop.
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