1:1 Millennium Falcon Cockpit Replica - Group Build

[SofaKing01]

Re: 1:1 Millennium Falcon Console Replica

Hi Gang...

I think I got it! Taking all of your suggestions I plowed ahead

I found the inner and outer measurements along with the differing / opposing angles

Marked them off

Using the foam core I drew the appropriate angles and cut out what basically looked like a trapezoid (I'll post a few more pics as I create the other side). Then found the curve by bending a ruler. holding it in place and had my lovely assistant mark the curve with a pencil (she said it was too early in the morning to have her pic taken).

It's not rocket science but I think it works

Aint that perty? Look at the front of the upper beam (connected at the window arch) you can see how warped it is

One of the beams is badly warped so I have to move the beams around to find the best placement. So far so good! In a few hours I will break out the power tools and transfer the templates to MDF, cut the vertical sides, figure out how to mount these to both the upper side wall and horizontal beam (I'll use the same method I used for the horizontal beams mounting to the window and back arch), then skin the inside with bendy board, paint, greeblie, etc... See... Easy Peasy

Should be a good day!

 

[laellee]

Re: 1:1 Millennium Falcon Console Replica

It's not rocket science but I think it works

I see what you did there....

 

[SofaKing01]

Re: 1:1 Millennium Falcon Console Replica

Hi Gang,

I wound up having to re-measure the top vertical arch due to the warping of the beam...

The first thing I did bolt the beam into place. This will keep it from rocking back and forth - that created the irregular measurements

I then counter sunk the bolt - I'll have to leave the hole when I skin the window

This is the rear part of the beam - this will eventually be covered by the top part of the canopy

With everything bolted in place I measured the angles and created a template - I cut the edges off

And slid into place - perfect fit

Then taking a ruler I bent to shape hoping to find the correct edge

LOTS of adjusting

That doesn't look too good...

Back and forth, back and forth, back and forth until I got the best edge possible

Traced the edge

Cut the foam core to shape

Transfer the template to MDF

3 more to cut for this side then we do the entire process over again

Once all of these are done, I'm going to add another layer of MDF on top (to include the horizontal beams). They will be separated down the middle by 1/8-1/4" following the curve of the beams to create the gap used for the windows.

More to Follow!

 

[SofaKing01]

Re: 1:1 Millennium Falcon Console Replica

Hi Gang,

Han's vertical beams are now built and skinned - waiting for the filler to dry to trim the board

MDF panels cut

Looks pretty good

The inner pieces matched the edge of the nose - cut to fit

Done

Side view

Inside

Looks pretty good from here

Skinned and out for a tan

On to Chewie's side... but I have no more foam core... Road trip...

EDIT - I have to do this for the top part of the canopy and the awkward angle piece as well (beginning of this page)

 

[SofaKing01]

Re: 1:1 Millennium Falcon Console Replica

Hi Gang,

The end of another day... I was only able to get 3 of the vertical beams built. Let's hope for good weather tomorrow...

As with any filler... it cracked when I sanded down the edges. But no worry. I filled with extra glue / filler and I will sand smooth tomorrow. But the edges look great and they marry up against the horizontal beams perfectly!

Still lots of filler need on this side

Chewie's side in the distance

Another of Chewie's side

Both sanded and in place

Alignment is near perfect! How did that happen?

I can't wait to show you guys what details comes next for the beams!

Chewie's side - curve looks pretty good - note the clear gloss tape around the window arch

I've taped down thin strips of wood helping them bend to take shape for the next fun details...

That's it for today... I'm wiped out...

 

[Kevlarr]

Re: 1:1 Millennium Falcon Console Replica

Just... Nice!

 

[trainman]

Re: 1:1 Millennium Falcon Console Replica

Bravo!! Love it!!

 

[SofaKing01]

Re: 1:1 Millennium Falcon Console Replica

do your 3D plans have measurements and angles? or just ratios? or what? To me it looks like you're going to need to cut and join lots of straight pieces, then round them off. And you'll need a compound miter saw for the end pieces to get that slanted angle.

Hi T,

I'm using Google SketchUp - that's what Starkiller uses for his 3D builds. Having the 3D model right in front of me REALLY helps - especially knowing that the from the side those vertical beams are actually straight up and down - the eye vs camera angles can be very confusing.

It looks like I've figured out the process... at least I hope so...

 

[SofaKing01]

Re: 1:1 Millennium Falcon Console Replica

You should use a quadratic equation to derive the incognita.

That's what I wanted to do... but the inverse reactive current for use in unilateral phase detractors didn't synchronize the very important cardinal grameters...

I think this explains it all...
http://www.youtube.com/watch?v=RXJKdh1KZ0w

So you see how confusing it was...

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...or just cast it off the real Falcon, it should fit. :lol

I never got passed security...

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Hi Greg,

The canopy seems to be a complete semicircle. If it is a perfect semicircle in the front and at the panels, the vertical beams should be part of another semicircle too.

The length of the batten placed horizontally is the diameter of the semicircles you need. You can take the inner and outer as well as the front and back side dimensions directly from the batten.

For the length of those beams you can then either calculate the radian by angles or simply measure if you make a cardboard template of these segments (of the resulting circles) first.

At least in theory LOL

Good luck!

Hi F,

THANKS! My original plan was to get the diameter of the fill half circular... But to be honest... I just didn't want to waste the money on all the material. After looking at all the suggestions I came up with the process I used. I think it worked...

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I see what you did there....

Imagine my approach in NASA?

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Just... Nice!

Thank you, Sir!

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Bravo!! Love it!!

Thanks! It took some brain cells but I'm really happy with the results...

 

[SofaKing01]

Re: 1:1 Millennium Falcon Console Replica

Hi Gang,

So I've been thinking how I'm going to attach the vertical beams. My first thought was to create a lip similar to how I currently mount the horizontal beams but I think I'm going to use the nut/bolt system I've been using for the panels - technically they mount into each other through the horizontal beams. Still looking at different options.

Bad news... weather looks bad... Play it by ear...

 

[SofaKing01]

Re: 1:1 Millennium Falcon Console Replica

Hi Gang,

Good news... the weather is holding but it is very overcast! Anywho, I decided on the nut and bolt approach to attach the vertical beams. I'm also making major progress on the details!

Bolts in place

Perfect alignment

As we all know... the cockpit DID in fact have a window. I think the window is present in several shots but was eventually removed because of glare and reflections. So, to stay screen accurate I am building the small "channel" where the glass would have slipped - and I'm hoping that should I decide to slip plexi in place - it will!

Creating the channel by cutting the sample template but then cut in half

One side done - turned out pretty good

Close up

Other side done

With the vertical "channel" skins in place I moved forward to the beam(s)...

Whoops... slightly wider... oh well...

Soaking pieces of trim in the tub - you'll see!

More to Follow - if the weather holds!

 

[laellee]

Re: 1:1 Millennium Falcon Console Replica

Looks amazing!
You should go pick yourself up some tagboard, you can trim your plexi templates as you go if you're pretty sure you'll add it later. Although now that I type this, I'm sure you'll have a chance to do this one of the MILLION times you assemble and disassemble the bohemoth!

 

[red4]

Re: 1:1 Millennium Falcon Console Replica

That's what I wanted to do... but the inverse reactive current for use in unilateral phase detractors didn't synchronize the very important cardinal grameters...

I think this explains it all...
Rockwell Retro Encabulator - YouTube

So you see how confusing it was...

I wasn't sure if it was a joke, until I clicked on the related videos. It's a corporate meme!

 

[SofaKing01]

Re: 1:1 Millennium Falcon Console Replica

Hi Gang,

The weather held long enough for me to run out of gas... I'm going to relax and enjoy some football and pizza

I really wanted to add more details but need to hold off. The window arch is causing me to think forward a few steps... Anywho...

More "channel details added

This was fun. Each one is slightly different so I had to make sure each piece not only lined up but was the same width as the piece it was marrying

It just seems to get bigger and bigger...

Still need to get to Chewie's side

Size Comparo - note the spray can on the garage floor

From this pic you can see where the middle of the window arch (the two different color paints) is NOT aligned with the horizontal side panel - so right now the window "channels" will not line up properly

The color on the beams gives you an idea how I'm going to paint the beams when everything is finished - the channel will be black

That's it for me today!

 

[SofaKing01]

Re: 1:1 Millennium Falcon Console Replica

Looks amazing!
You should go pick yourself up some tagboard, you can trim your plexi templates as you go if you're pretty sure you'll add it later. Although now that I type this, I'm sure you'll have a chance to do this one of the MILLION times you assemble and disassemble the bohemoth!

Thank you! Now that I'm doing the window channels (whatever they're called - lol) I definitely want to add plexi! Later down the line I'm going to get some cardboard and see if I create templates and slip them into place. Should be fun!

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I wasn't sure if it was a joke, until I clicked on the related videos. It's a corporate meme!

Yeah... Sorry... I was little out of sorts... I love the video!

 

[red4]

Re: 1:1 Millennium Falcon Console Replica

I mean, I knew you linked it as a joke; but I wasn't sure if the video itself was created as a joke... until I saw the related videos.

 

[Yodamann]

Re: 1:1 Millennium Falcon Console Replica

It just seems to get bigger and bigger...

I think there's a very good reason for that!

 

[flthymcnsty]

Re: 1:1 Millennium Falcon Console Replica

This is the coolest thing I have seen in a very long while. Amazing work.

 

[SofaKing01]

Re: 1:1 Millennium Falcon Console Replica

I think there's a very good reason for that!

It's becoming more solid as well - that's a good thing

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This is the coolest thing I have seen in a very long while. Amazing work.

Hi F,

Thank you so much. This weekend was alot of fun. I enjoy the basic build, but it's the details I enjoy most. That's when you finally see all the hardwork begin to pay off. Still have LOTS to do...

 

[Bigdaddy]

Re: 1:1 Millennium Falcon Console Replica

WOW SK, this blows me away everytime I check in! Love the canopy and the pics from the builder faire. cool