Thunderbird 1 Pilot Chair

We created a replica of Thunderbird 1’s puppet-scale pilot chair, as seen in the original 1960s Thunderbirds TV series.

The process involved

• modelling 3D blueprints against original film stills, extrapolating lens length and camera position

• sourcing vintage model kit and automotive parts used on the original

• moulding and casting parts

• construction using plywood, polyurethane resin, aluminum and brass sheet

• creating custom red vinyl upholstery using stamped EVA foam

• painting and finishing 3D printed parts

Our replica chair is featured in Thunderbirds promotional material for Anderson Entertainment and won Best in Show at the 2022 Toronto Prop Expo.

With thanks to our fellow propmaker friend Hilton Fitzsimmons for helping us source the same vintage parts used on the original chair.