After Mark Dickson shared photos from the set of season 4 episode "Play Ball" I became obsessed with making a handlink replica. Years ago I drew some cad drawings and over the years I refined them over and over again. Tracking down some of the little LEDs was a quest many QL fans pursued, but after watching and seeing how rare those leds were, I decided to CNC machine from aluminum all the tiles. My plan was to make molds and cast the parts in transparent resin
I ended up with this crude model
Not happy I decided to try the laser cutting route, and sent my cad drawings to a company to do the cutting. I got a few samples cut, but the quality was poor and without actually being there in their office, I could not fiddle with the size adjustments to compensate for the beam width on different power settings. It became apparent that I would need to buy a laser cutter and do it my self. So this year I took the plunge and purchased one from ebay.
After a little experimenting and learning the new machine, I came up with a mock up of the handlink body. This was and is still in the testing phase as I still needed to gather all the data on the electronics and light channeling.
But for a first cut, it was exciting.
I then went on to create another mock up of all the tiles to make sure before I committed to the full size color acrylic, it all fit together.
Happy with that, I purchased all the color acrylic and one by one cut batches of each tile.
Some colors were wrong (and still are, specifically the green) but it slowly came together.
I wont post the hundreds of photos I took during the process, you can see them here if you want. https://www.facebook.com/replicapropscom/
I am not done yet, I still have to find the proper green and work on the electronics, but I wanted to share what I have done to date with people who love the show.
Hope you enjoyed seeing the story of this prop replica.


I ended up with this crude model

Not happy I decided to try the laser cutting route, and sent my cad drawings to a company to do the cutting. I got a few samples cut, but the quality was poor and without actually being there in their office, I could not fiddle with the size adjustments to compensate for the beam width on different power settings. It became apparent that I would need to buy a laser cutter and do it my self. So this year I took the plunge and purchased one from ebay.

After a little experimenting and learning the new machine, I came up with a mock up of the handlink body. This was and is still in the testing phase as I still needed to gather all the data on the electronics and light channeling.
But for a first cut, it was exciting.


I then went on to create another mock up of all the tiles to make sure before I committed to the full size color acrylic, it all fit together.

Happy with that, I purchased all the color acrylic and one by one cut batches of each tile.

Some colors were wrong (and still are, specifically the green) but it slowly came together.

I wont post the hundreds of photos I took during the process, you can see them here if you want. https://www.facebook.com/replicapropscom/
I am not done yet, I still have to find the proper green and work on the electronics, but I wanted to share what I have done to date with people who love the show.




Hope you enjoyed seeing the story of this prop replica.