Trevor/Behind the Scenes

"Small Scale Model"
The model was built to run on Styrofoam road and was painted in glossy car body paint.

Three different facial expressions were worn by Trevor on screen. The faces were first sculpted in clay and from that resin casts were made using a silicone mould. A radiator was attached to each of Trevors facemasks.

In the Second Series, Trevor did not have eye mechanism and his eyes remained static until the third series. The eye mechanism had two servos, one for up and down movement and one for left and right movement. The up/down servo was attached to the body. The left/right servo had a rod attached to the arm, which connected to a bracket. The eye balls were coupled to the bracket and locked in by the face-plate, so whenever the servos were powered, the eye balls would move however the crew member desired.

"Large Scale Model"
For ease of filming and reliability, The Pack introduced larger-scale version of Trevor and for the ninth series, this larger model was used almost exclusively. He were built to a larger scale. He was close to 16mm scale, but slightly larger.

The model was made from brass. The wheels and chassis were custom machined (CNC). The model was track powered, so pickup contacts were attached to the metal wheels, which ran into the motor to power it. The electricity ran from the track to the wheels/pickup contacts and went into the motor to power him. The model was also fitted with a smoke unit.

The eye mechanism had two servos, one for up and down movement and one for left and right movement. The up/down servo was attached to the body. The left/right servo had a rod attached to the arm, which connected to a bracket. The eye balls were coupled to the bracket and locked in by the face-plate, so whenever the servos were powered, the eye balls would move however the crew member desired.

"CGI Model"
In 2009, the series introduced Computer-Generated Imagery (CGI) as a replacement for the show's long-standing live-action models. Trevor was recreated from scratch in CGI by Nitrogen Studios. His model was "hand-sculpted" in Maya, a 3D animation and modelling software.

Photographs of Trevor's small scale model were used for referencing. According to Greg Tiernan, every detail of the original television series models for each character is carefully reproduced in the CGI model. The models are subjected to many rounds of review before they are submitted to HiT Entertainment for final input and approval.