Scroggins 2017 HIC Han in Carbonite Build Thread

Scroggins

New Member
While this isn’t the first, and certainly won’t be the best Han in Carbonite HIC build thread, I wanted to take the time to document and post my journey as each thread I’ve found has been helpful in some way. As I've researched my project I have constantly found myself wishing that there would have been even more build threads available as they are all slightly different and I've gotten different ideas of things I like and things I don't from each.

I’ve got a lot of work still ahead of me but wanted to get started and share where I’m at. Like others this is my attempt at trying to follow bits and pieces of other builds that looked like they’d work for me. There are three build threads in particular that I’ve already read and reread multiple times, so thanks @QCWolf @Bigturc @FrightMaker for starting those and adding so many detailed steps and pictures. I'll try to do half as well!

Little background.....Other than halfway completing my TK build, this is my first prop build of any sort. Just putting that out there for other novices and beginners that may be thinking of trying to pull this off as you'll be able to see any of my successes and failures! I’m making this for me. Not to be the most accurate 1:1 replica ever built. I’m going to stick close, but not get too hung up on perfection and will prob have mult hero panels (cuz they’re cool) or take other allowances where/when needed!

Anyway….
Here’s the main parts I’ve acquired so far including costs. I’ll come back and add in the details on the rest as I get there. I'll also try to put a total list of all the tools I've had to use.

Box: @zenix (alreadypurchased and delivered) – Highly Recommend - $288 (posts 5,9,16,18)

Han Cast: @KingJawa (already purchased and delivered) – $240 ------- This has since been returned (see post 29). Replaced with a Stormrider full rubber front.

Panels: Halloweenking999 (ebay purchased and delivered) - $150 (see post 26). Broke 2, so ended up getting a few extra panels from Stormrider.

Greeblies – Purchased Zenix greeblies from Shapeways as well as his metal grill and clips.

Paint colors:
Box –Rustoleum dark steel (thx @QCWolf)
Panels – Base coat Rustoleum oil rubbed bronze, Top coat Rustoleum Antique Nickel (see posts 26 & 28)
Front – Either Rustoleum Forged Hammer Antique Pewter
Weathering - Black acrylic wash

Panel Lighting– Fettronics kit for panel 1 & 2

Back Lighting –self adhesive color changing LED’s from Amazon.

Mounting – TVmount

I plan to make this pretty pic heavy and am open to any and all feedback and criticism. Will really appreciate any ideas and suggestions along the way!
 
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Before I knew anything I bought the panels from the same ebay person. They were junk, complete crap. I recently bought Zenix panels which are top notch. Probably saved my a few months of prep. Those ebay ones were bad.
 
So this arrived…

What’s in the box (Brad Pitt 7even voice)?
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This would be the Zenix CNC cut box. Comes wrapped andpacked very securely. He’s got great instructions in his for sale thread on how to put it together that are pretty good. First thing I did was layout all of the pieces and then dryfit the pieces to see what things were looking like.
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While it was a pretty good fit, things weren’t quite flushing up. This is covered in the instructions and is a result of the rounded bit and how it leaves the inside corners during the CNC process. It only took a couple minutes to file them square using a wood file.
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After filing everything down I confirmed everything was now flush with another dryfit run and then moved on to gluing the puzzle pieces together. I used Gorilla wood glue on the puzzle pieces and then clamped them together over night.
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Before I knew anything I bought the panels from the same ebay person. They were junk, complete crap. I recently bought Zenix panels which are top notch. Probably saved my a few months of prep. Those ebay ones were bad.

I figured they weren't as good as the others as they were only $150 shipped but I don't really have anything to compare them to. They fit the box opening and I figure a coat of primer and some paint and they should work? What did you find to be unusable to the point of getting new ones?
 
I figured they weren't as good as the others as they were only $150 shipped but I don't really have anything to compare them to. They fit the box opening and I figure a coat of primer and some paint and they should work? What did you find to be unusable to the point of getting new ones?

I got them a few years ago, they were fiberglass and needed a lot of sanding and fill. Some of the detailed lines were broken. The Zenix ones are perfect.

I'm also currently building mine. I plan on doing a build log once finished. I need a router at the moment.
 
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I got them a few years ago, they were fiberglass and needed a lot of sanding and fill. Some of the detailed lines were broken. The Zenix ones are perfect.

Gotcha. Well they are definitely still fiberglass however they may have an updated mold they are working from. Lines seem "good" and I don't see any areas to fill (aside from the minor gaps between the outside of the panel and the box but I think those are pretty much universal). I'm going to give one some primer and paint and see if I can use them, would be nice to save some $ somewhere! I'll post pics of them for sure as I move through the build.
 
Next step was to start putting the frame together. Used the Gorilla wood glue again, and some 3 foot clamps on each end to help hold it in place while it dried.
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After I let that dry overnight it was time to brace the corners as the whole thing is pretty fragile at this point. I was initially going to use L brackets as I'd see in a few threads, but in each of those threads more wood bracing was eventually used in some fashion. I decided to just go with the 2x3 supports that I'd seen in many of the builds and was originally provided with the early Zenix kits. I ended up using two in each corner and one on the middle of each side to help reinforce where they were glued together.
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I knew I was going to want to countersink my screws so I ended up buying a Dewalt countersink drill bit as it made the process go quicker than switching bits in and out. I used some deckmate 1 5/8" wood screws I had left over from another project. They worked well but 1.5 or 1.25 inch would probably have worked just as well.
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Before I knew anything I bought the panels from the same ebay person. They were junk, complete crap. I recently bought Zenix panels which are top notch. Probably saved my a few months of prep. Those ebay ones were bad.

UGH. They also sell a sub $200 resin cast of Han. I hope it's not crap too. I've already paid for it.
 
Thanks for doing this. I'm building mine soon and this will help ALOT!

Reel


Sent from my iPhone using Tapatalk
 
So next step was to get the front panel ready (the piece I will ultimately attach Han to). So I got a piece of plywood roughly cut to size at Home Depot....yeah I know that's lazy, but they make free cuts and my wife had the SUV so I had to find a way to get it in my car because I wanted it NOW. Anyway, I took the frame I'd built to that point and laid it down over the top of the plywood and used a marker to roughly draw outs the cuts I'd need to make for it to slide down and fit with the side and corner braces I'd already screwed in.
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Next I decided to get the top frame/trim added so that when I cut the plywood I'd be able to get it attached. Picture below is just a random pic of the frame attached. What you can't see and I didn't get a good picture of was that while the frame went on easily, due to the angled sides I did have to shim the corners. This was not hard or a big deal, but was important for the frame to sit level as the corners are all angled. I just bought a pack of cheap builder shims, wedged them in until everything was square and screwed it in. You can see a few of them in the pic below. Once everything was screwed down I just went back around and broke the excess off.
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As I was getting ready to add the plywood front, I realized that the sides between the middle and corners had some "give" so I decided to add a few more supports. These were just small pieces of 2x3 I had left and just enough to get screws through the side and then down through the top frame to help lock everything down. you can see them in the pic above and also below. By adding these I had to refit my front piece and cut out new openings so it would fit again.
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Finally things were ready to go and so I put down a good pattern of the wood glue and dropped the sheet in place. I went around the edges and gave myself a little guide of where the trim ended so I could screw the sheet up into the front trim.
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As I was admiring my hard work I thought I caught a glimpse of a dimple on my trim....Now I know I had measured twice and even went back to home depot to get short enough screws as I was concerned with having them too long and popping through the front trim, but if they were too short I was worried it wouldn't hold well enough...After all that thought though I apparently had built up my raw strength and while screwing through the plywood I penetrated too deep a few times (insert inappropriate humor) and I got some dimples on the frame...never broke the surface and was easily fixed by backing the screws out a twist or two. Disaster #1 averted (lets hope this is the only one!)
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Added a few 1x3 braces across the back in between the supports to help ensure no sag. Not sure if it was needed or not but I figured why the heck not at this point.
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Finally took some 1/4 inch plywood and cut "backs" for all the panel holes. I also decided to just put panels in on the top and bottom as well. I couldn't seem to find any of the "plugs" and I told myself nobody will ever see the top/bottom once it is up on the wall anyway so rather than try to figured I'd just forget about them rather than try to MacGyver something together that would probably cause me a bunch of headache for no good reason. I placed two holes in the top (near Han's head) two panels on each side giving me room to add electronics as I deem appropriate (thinking I might do both sides).
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That's essentially it for my box construction. I'll come back and add two more supports on the back edge of the box for me to place my TV mount and will post a pic when I do (waiting on my mount to arrive so I space them appropriately). Next step is BONDO and sanding time!
 
If Zenix still sends the same material, that box is made out of 1/2" MDF .. did you think about inserting a 1/8" or 3/16" sheet to remove some of that height? It's almost a must if you want to have that nice flush carbonite effect with the sides.
 
If Zenix still sends the same material, that box is made out of 1/2" MDF .. did you think about inserting a 1/8" or 3/16" sheet to remove some of that height? It's almost a must if you want to have that nice flush carbonite effect with the sides.

Yep! Have a sheet ready to go! That's the best thing about having all these threads to read, You get to learn so much from the early builders and the tips/tricks they came up with along the way to make things easier for those of us now! It's such an obvious idea in retrospect...always easier to be a Monday morning QB!
 
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