1:1 Millennium Falcon Cockpit Replica - Group Build

Discussion in 'Star Wars Costumes and Props' started by SteveStarkiller, May 7, 2012.

  1. SofaKing01

    SofaKing01 Master Member

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    Hey L,

    I can try bending the MDF in the opposite direction but I wonder how much more manipulating I would have to do? Either way, I plan to cover the MDF with a single layer of styrene to get that smooth finish and all the acrylic greeblies will adhere.
     
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  2. SofaKing01

    SofaKing01 Master Member

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    Thanks, LtW! Any help is ALWAYS appreciated! :)
     
  3. SofaKing01

    SofaKing01 Master Member

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    Hey JM,

    Thanks for the kind words!

    Yup! That's the plan. I originally started doing the 1/4 scale version 1) out of enjoyment 2) nobody had ever done it and 3) the full scale version is down in Texas getting some new clothes! ;)

    Fellow RPFer Izzy convinced me to begin work on a 1/6th scale version to accompany the 1/6th scale community. We've had some serious interest in the 1/6 kits so we're very excited to get it finished and delivered to those interested.
     
  4. SofaKing01

    SofaKing01 Master Member

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    Hey JB,

    Thanks! I agree. I'm glad I took the time to double up the trim. It DEF adds the bulk needed to frame in the windows.

    The more I think about it the more I'm leaning towards fiberglass. If I can find a cheap glass tabletop to use as the working surface the glass will be mirror smooth minus any imperfections I may miss.
     
  5. SofaKing01

    SofaKing01 Master Member

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    I haven't slept in 4 days!
     
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  6. JediMichael

    JediMichael Sr Member

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    So then you can put the 1/6 figuers in it I'm guessing. So not being good at scale size, or math. Wondering, what scale would the 5 foot model be at and would yours be bigger.
     
  7. SofaKing01

    SofaKing01 Master Member

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    Hi Gang,

    Part III - The Vertical Beams

    I finally got around to creating the 1/4 scale canopy vertical beams
    IMG_20181123_102617_zpsu0o9m2ts.jpg

    Because of the layers of styrene, gravity and humidity, the angles of course were all slightly off so there was a LOT of reworking /sanding / cutting to do
    IMG_20181123_102622_zpswkw7ogks.jpg

    IMG_20181123_103851_zpsp2oe5kcb.jpg

    Edges cut
    IMG_20181123_103857_zpsmuzkkdca.jpg

    IMG_20181123_103904_zpsiv6d9auv.jpg

    Love it!
    IMG_20181123_103919_zpse8qle0sf.jpg

    IMG_20181123_110000_zps3vb6gbnu.jpg

    Going back to the "For Sale" signs I skinned each beam
    IMG_20181123_114011_zpswbztkio8.jpg

    Added the interior trim
    IMG_20181123_113445_zpsquewbecq.jpg

    IMG_20181123_113456_zpswx17jt7i.jpg

    Making sure it still fits!
    IMG_20181123_113521_zps79h3fd9u.jpg

    IMG_20181123_113530_zpsgj6pagtl.jpg

    Filler
    IMG_20181123_113959_zpslmrgd15y.jpg

    IMG_20181123_114006_zpsnzm5vd8p.jpg

    Same process for the upper beam
    IMG_20181123_115924_zpshuipwlsy.jpg

    IMG_20181123_115930_zps57qiz48o.jpg

    IMG_20181123_115956_zpsl9jzq190.jpg

    IMG_20181123_120005_zpsrx0ksxgm.jpg

    IMG_20181123_120050_zpskvqxsscd.jpg

    IMG_20181123_120054_zps4j31p9od.jpg

    Part IV Below
     
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  8. SofaKing01

    SofaKing01 Master Member

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    Part IV - The Vertical Beams (Cont'd)

    Lots and lots of filler
    IMG_20181123_133728_zpsdfgrgohd.jpg

    Primer!
    IMG_20181123_133744_zpsqt8jp1fa.jpg

    MMMMM Primer
    IMG_20181123_133752_zpsgjezjoh2.jpg

    IMG_20181123_133802_zpspqhlzpfv.jpg

    The outer edges of the beams are perfect!
    IMG_20181123_142938_zpsvgdov7is.jpg

    Han's side
    IMG_20181123_142944_zps2xefphxj.jpg

    IMG_20181123_142951_zpshue1vwaz.jpg

    IMG_20181123_142959_zpslpf1plsj.jpg

    I then added an extra layer of styrene on two side to help blend the edges between the trim and the beam
    IMG_20181124_084053_zpsx2gcbqdw.jpg

    IMG_20181124_084056_zpslrcsugr3.jpg

    Finally... I cut the styrene to fit and added filler
    IMG_20181124_084104_zpshnfqbfi6.jpg

    What the heck... Part V Below! ;)
     
    Last edited: Nov 28, 2018
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  9. SofaKing01

    SofaKing01 Master Member

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    Part V - Vertical Beams and the Canopy Windows

    I continued my adventure by skinning the sides of the canopy window openings - applied tape and cut
    IMG_20181124_091541_zpsko6bsvxr.jpg

    The tape acts as a template
    IMG_20181124_091547_zpssunvelee.jpg

    Remove the tape and adhere to the styrene
    IMG_20181124_091759_zps10tm9ojx.jpg

    I cut the ends that were perfectly aligned with the tape but gave the interior / exterior edges some extra play
    IMG_20181124_091846_zpsavgopxdd.jpg

    Adhered into place
    IMG_20181124_091856_zpsnpuzrhpx.jpg

    Trimmed the excess
    IMG_20181124_092840_zpszsfkhtif.jpg

    Oh boy... Lots of filler needed on these corners
    IMG_20181124_092845_zpssskawwfq.jpg

    I continued the process
    IMG_20181124_093201_zpsswpi1wop.jpg

    IMG_20181124_093654_zpsnsvi39hq.jpg

    IMG_20181124_093657_zps9iv9vhbk.jpg

    Filler!
    IMG_20181124_102000_zpsoalxckj2.jpg

    IMG_20181124_102006_zpscqelzwzy.jpg

    IMG_20181124_103943_zpsogltk9jv.jpg

    Vertical beams slowly coming along
    IMG_20181125_153808_zpslrf9tpp4.jpg

    Once the vertical beams are permanently adhered, I'll fill in the small gaps
    IMG_20181125_153813_zpsubwlzvhy.jpg

    IMG_20181125_153821_zpseswbwc67.jpg

    IMG_20181125_153829_zpsyyyy8a7e.jpg

    I was strongly considering adding windows but decided against it... maybe next time
    IMG_20181125_153833_zpsxg4afoto.jpg

    And this is where we are!
    IMG_20181125_153839_zpsguw3wnch.jpg

    Part VI - Coming!
     
  10. SofaKing01

    SofaKing01 Master Member

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    Hi Gang,

    Time for Part VI

    I designed and laser cut these odd looking shapes
    IMG_20181124_123401_zpswlboakyz.jpg

    I sanded and put them together
    IMG_20181124_123745_zpshxua1udg.jpg

    Hey Now... we have the start of the cockpit entrance... FINALLY!
    IMG_20181124_130122_zps3cymq0qj.jpg

    IMG_20181124_130129_zpsvry9o94x.jpg

    IMG_20181124_130651_zpsyfu8wlgx.jpg

    I temp added the older corridor ring and everything still fits!
    IMG_20181124_131314_zpspcejowfn.jpg

    Part VII Below
     
  11. SofaKing01

    SofaKing01 Master Member

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    Part VII - A New Corridor Ring

    I spent several hours at the computer cleaning up files and getting to the point where I can begin cutting! The result?
    IMG_20181125_074751_zpscm1diyia.jpg

    A new corridor ring!
    IMG_20181125_074757_zpsmufiyzq2.jpg

    IMG_20181125_074821_zpscejokwph.jpg

    IMG_20181125_074827_zpshneirssc.jpg

    I laser cut these VERY thin trim pieces
    IMG_20181125_074837_zps4ebjdvar.jpg

    They will eventually be adhered and go all the way around the ring
    IMG_20181125_074906_zps7zkxffwo.jpg

    Choo Choo
    IMG_20181125_074912_zpscmnfl70a.jpg

    I made the mistake and adhered the trim too soon...
    IMG_20181125_092227_zpsvrltft07.jpg

    Interior supports
    IMG_20181125_101518_zpsa0bbmph6.jpg

    Broke out some more "For Sale" signs and cut to fit
    IMG_20181125_121314_zpsmkxafmkq.jpg

    IMG_20181125_121407_zpsyzuqprhi.jpg

    Once I cut away the excess styrene I taped off the edges for 2 reasons...
    IMG_20181125_123200_zpsi5j455fm.jpg

    Using the older corridor as a template I cut the 3rd piece of styrene but left some extra on either end
    IMG_20181125_123309_zps35eprvoc.jpg

    The edges of the blue tape showed me exactly where to cut the excess
    IMG_20181125_123321_zpswdybbpdn.jpg

    PERFECT!
    IMG_20181125_123408_zpszb2jwcv2.jpg

    The 2nd reason for the tape was to spray both surfaces, styrene and MDF, with 3M adhesive and mount - the tape prevent any over spray
    IMG_20181125_123408_zpszb2jwcv2.jpg

    I cut all the holes for potential wiring
    IMG_20181125_124224_zpsdwrbzf3t.jpg

    IMG_20181125_124228_zpspgy8pfps.jpg

    This is where I messed up by adhering the trim pieces to the ring - I skinned the interior of the ring
    IMG_20181125_130755_zpstk0rgijy.jpg

    This made trimming the skin VERY difficult. I'm going to remove the trim this weekend, clean up the edges, recut and reapply
    IMG_20181125_130803_zpsqn7siew2.jpg

    More to Follow!
     
    Last edited: Dec 4, 2018
  12. Hostamon

    Hostamon Member RPF PREMIUM MEMBER

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    At one time there was a trainer console. :) It probably got junked after the Skylab missions ended or it could be sitting in the basement of a retired NASA engineer waiting to be discovered!
     
  13. SofaKing01

    SofaKing01 Master Member

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    Hi Gang,

    Time for Part VIII - A Familiar Shape

    Aside from the new corridor ring I laser cut these familiar shapes
    IMG_20181125_092220_zpsj2ixoplv.jpg

    IMG_20181125_095458_zpsafmvowrp.jpg

    Interior supports
    IMG_20181125_095506_zpss3zbs9hx.jpg

    Panel
    IMG_20181125_101522_zps4e731jxv.jpg

    Gee that looks familiar...
    IMG_20181125_101547_zpse40nmu9f.jpg

    IMG_20181125_130824_zps4dtipsis.jpg

    Acrylic details and panel faces
    IMG_20181125_131622_zpsiutlwlnd.jpg

    IMG_20181125_131700_zps4rdkjrnc.jpg

    IMG_20181125_131716_zpscdtkrjdy.jpg

    IMG_20181125_131741_zpsvgfesqqr.jpg

    IMG_20181125_133503_zpsnt6t3z3p.jpg

    IMG_20181125_133512_zpsthqt06me.jpg

    IMG_20181125_133534_zpsc81n7h0x.jpg

    I laser cut this acrylic mess
    IMG_20181125_133219_zpsxd2zcymj.jpg

    IMG_20181125_140552_zpsoteimmvw.jpg

    Tough to see the basic shape
    IMG_20181125_140601_zps96h3faeq.jpg

    Another greeblie
    IMG_20181125_142505_zpsyjtfpqyv.jpg

    IMG_20181125_142633_zpsr5tklkpb.jpg

    Primer!
    IMG_20181125_144539_zps18ziydph.jpg

    IMG_20181125_144551_zps8fslynwk.jpg

    Part IX Below
     
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  14. SofaKing01

    SofaKing01 Master Member

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    Part IX! :)

    That's better...
    IMG_20181125_144608_zpsarm1pho9.jpg

    More panels
    IMG_20181125_150438_zpsge7211qi.jpg

    IMG_20181125_151556_zpsairrkien.jpg

    IMG_20181125_151602_zpskyarbetp.jpg

    Over 10" tall
    IMG_20181125_151633_zpsqpyxidk5.jpg

    IMG_20181125_153231_zpsh4xzbido.jpg

    IMG_20181125_153236_zpsjbonersj.jpg

    And this is where we are...
    IMG_20181125_153242_zpshpc7efd0.jpg

    Just wanted to let you all know that me and fellow RPFer Izzy, with the help and encouragement from Fuzzual, are getting ready to start our own YouTube Channel! The channel will focus not only on the full scale cockpit build and the smaller scaled down versions of the cockpit but also other little projects we're working on like the nav computer, other MF related parts and anything SW/SciFi related projects! More details to come!

    We'll always be updating the RPF but we hope that all of you follow and join us for the next chapter of our adventure!

    As always... More to Follow!
     
  15. IzzyMel

    IzzyMel Well-Known Member

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    Loving all the detail that you are putting into this
     
  16. Mad Monkey

    Mad Monkey Well-Known Member

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    That laser cutter must be a God send!
     
  17. SofaKing01

    SofaKing01 Master Member

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    Hi Gang,

    Time for the "End of the Weekend Update" in 3 Parts! ;)

    Part I - A New Direction

    The MDF skin I cut just wasn't working so I broke out the fiberglass and got to work!
    IMG_20181201_084144_zpsz4yqvz44.jpg

    Made sure the glass mat fit with the pencil lines
    IMG_20181201_084149_zpsg5ba4ffw.jpg

    Mixed the resin
    IMG_20181201_084158_zpsvtmeu2kc.jpg

    Now we wait for the resin to "begin" to cure
    IMG_20181201_090423_zpskguvtfhy.jpg

    I laid wax / parchment paper across the cockpit
    IMG_20181201_090655_zpst3tvtvfk.jpg

    At a certain point the resin cures where you can touch it but the glass is still flexible. I laid more paper across the fiberglass then laid the MDF over the paper
    IMG_20181201_091625_zpsppqwpgvy.jpg

    I then cut along the lines of the MDF and removed the excess fiberglass leaving me with nice straight lines!
    IMG_20181201_092411_zps35t2xffd.jpg

    I gently picked up the glass and draped it over the cockpit and taped the edges in place
    IMG_20181201_093804_zpspcmqavxi.jpg

    I didn't get the glass as smooth as I wanted but both the interior and exterior will be covered with styrene so not too worried about it
    IMG_20181201_093810_zpszqnqbc9z.jpg

    Nice!
    IMG_20181201_093821_zps5pcnqek3.jpg

    IMG_20181201_122225_zpsdi9s5rip.jpg

    IMG_20181201_122230_zpshyokqvyn.jpg

    IMG_20181201_122237_zps4k0mcgyz.jpg

    IMG_20181201_122253_zpspn2cn2co.jpg

    Once the fiberglass cured I removed in prep to lay another layer of glass
    IMG_20181201_122029_zpshqvtm7kc.jpg

    Part II - Below
     
  18. SofaKing01

    SofaKing01 Master Member

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    Part II - Getting Kits Ready

    As I've mentioned I am starting to make kits of the 1/4 and 1/6 scale consoles. Eventually the cockpit might become a kit as well... But for now, I'm working the consoles and the Nav Chairs. Here is the final Nav Chair prep kit going to Izzy for testing
    IMG_20181201_122529_zpsfjppbknu.jpg

    IMG_20181201_122535_zps6btyjhv5.jpg

    Some styrene options as well
    IMG_20181201_140842_zpsbhqsspwo.jpg

    I was FINALLY able to find that sweet spot on the laser cutter settings to cut styrene
    IMG_20181201_140854_zpsfwiwocm9.jpg

    Acrylic - same parts but just a bit too thick in some places
    IMG_20181201_140909_zpsaoobando.jpg

    I'm also including a base for the console to sit
    IMG_20181202_135904_zps1drg5aav.jpg

    IMG_20181202_135910_zpsnirrl9p2.jpg

    IMG_20181202_140422_zpspc0o8xfx.jpg

    IMG_20181202_140428_zps3tuwaxmc.jpg

    IMG_20181202_140432_zpssrklgnus.jpg

    Top layer of MDF has the look of the corrugated mat
    IMG_20181202_140447_zps4afpx2kf.jpg

    Tight fit!
    IMG_20181202_142412_zpsbjztdmb6.jpg

    1/4 Scale kit going to Fuzzual who will be highlighting this project on his YouTube channel!
    IMG_20181202_152549_zpslxoko5nn.jpg

    Part III Coming! Stay Tuned!
     
    Last edited: Dec 3, 2018
  19. Lt Washburn

    Lt Washburn Active Member

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    Great work!
     
  20. DesertDan

    DesertDan New Member

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    Just finished all 209 pages, absolutely amazing!
     
  21. SofaKing01

    SofaKing01 Master Member

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    Thank you, my friend! Doing my best!
     
  22. SofaKing01

    SofaKing01 Master Member

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    Hey MM,

    Greatest investment I ever made! As I have mentioned a few times, the laser cutter literally changed the way I approached the build. I could finally create all the little details that I was unable to do when I first started out. And the size of it... that's where I really lucked out! It wasn't cheap but I dont regret buying it at all!
     
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  23. SofaKing01

    SofaKing01 Master Member

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    Thanks, LtW! Fingers crossed the fiberglass shell works out. I still have to do the bottom side and the nose but I have a good feeling...
     
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  24. SofaKing01

    SofaKing01 Master Member

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    Hey DD,

    WOW! Thanks for taking the time to read all those pages/posts! Now, there will be a written exam with 50 multiple choice questions and 3 essay questions. ;)

    Welcome to the RPF! Stay tuned for more updates and I hope you join us over on the new YouTube channel - COMING SOON!
     
    Last edited: Dec 7, 2018
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  25. SofaKing01

    SofaKing01 Master Member

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    Hi Gang,

    PART III - More Glass

    I added another layer of fiberglass to the exterior body skin
    IMG_20181202_091641_zpsc7t1tb9n.jpg

    IMG_20181202_091652_zpspcp17hp5.jpg

    IMG_20181202_091658_zps6rrstlpo.jpg

    Once the resin cured I removed the skin and cut/sanded the edges smooth
    IMG_20181202_123636_zpsqnmk8nw4.jpg

    IMG_20181202_123644_zpszy26clnp.jpg

    IMG_20181202_124056_zps2qccy1it.jpg

    YUCK! DEF needs more work...
    IMG_20181202_124101_zpsjarsa1a0.jpg

    IMG_20181202_124115_zpsegznuljg.jpg

    And this is where we are!
    IMG_20181202_124122_zpsvpxaies9.jpg

    What's next? I have to glass the bottom part of the skin/cockpit tube and the nose!

    Stand By! More to Follow
     
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  26. kickman88

    kickman88 Active Member

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    I was imagining you wrestling these huge sheets of fiberglass...and then the roll of tape reminds me it is not full size...but she is gorgeous!
     
  27. Mad Monkey

    Mad Monkey Well-Known Member

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    The scale perception is a tricky one for sure! Thankfully common items help! I love it
     
  28. SofaKing01

    SofaKing01 Master Member

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    Hi Gang,

    Quick update... I created a new fiberglass half to the main tube/exterior skin
    IMG_20181206_060408_zpssk92xugl.jpg

    IMG_20181206_060417_zpsmrjynlhh.jpg

    This one is slightly thicker than the first one. It took forever to cure because of the cold
    IMG_20181206_060843_zpskiyyab01.jpg

    I tried making this one slightly longer than the previous so the two would overlap when laid into place
    IMG_20181206_060906_zpshthbhlvp.jpg

    IMG_20181206_060911_zpsijjrzns6.jpg

    And that's where we are!
    IMG_20181206_061046_zpslpwodlz1.jpg

    More to Follow!
     
  29. Yodamann

    Yodamann Active Member

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    So is the plan for the full scale skin to also be cinemas like fiber glass?
     
  30. SofaKing01

    SofaKing01 Master Member

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  31. SofaKing01

    SofaKing01 Master Member

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    Thanks K!

    OH MAN! Can you imagine covering the full scale in fiberglass? Fortunately for us we're using 4x8 sheets of PVC. We should have some serious progress images VERY SOON
     
  32. SofaKing01

    SofaKing01 Master Member

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    Hey MM,

    I'm going to start taking images of the 1/4 scale in the usual full scale position to see if I trick everybody! ;)
     
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  33. SofaKing01

    SofaKing01 Master Member

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    Hey Y,

    Not sure I understand the question?
     
  34. Yodamann

    Yodamann Active Member

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    I'm gonna blame autocorrect on that one. I meant to ask "So is the plan for the full scale skin to also be sheets of fiber glass", but I see now that you said you're using PVC sheets
     
  35. kamandi

    kamandi Active Member RPF PREMIUM MEMBER

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    My brain just went pop. Please PM me details for the 1:6.
     
  36. SofaKing01

    SofaKing01 Master Member

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    Hey K,

    That's EXACTLY what I want your mind to do! ;) PM on the way!
     
  37. SofaKing01

    SofaKing01 Master Member

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    Hey Y,

    No worries. That's the plan. I'll be headed out to Dallas (along with Colorado) very soon to catch up with Ken & Mitch and the full scale cockpit.
     
  38. BruceKenobi

    BruceKenobi Active Member

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    Hey Guys! just as kind of a side note, what pieces are these:
     

    Attached Files:

  39. joberg

    joberg Master Member

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    Looking good Greg, looking good(y)
     
  40. SofaKing01

    SofaKing01 Master Member

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    Hi Gang,

    No "End of the Weekend Update" this time around. Sorry. I've been busy working on the instruction manual for the 1/4 and 1/6 scale console kit.

    BUT even better! Our YouTube channel "...What a Piece of Junk..." is FINALLY up and I posted our first vid. It's just a "Coming Soon" video so please check it out, Share, Like and Subscribe!



    More to Follow!
     
    Last edited: Dec 12, 2018
  41. teecrooz

    teecrooz Master Member RPF PREMIUM MEMBER

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    First Subscriber!
     
  42. Katuna

    Katuna Jr Member

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    Perscribed!
     
  43. SofaKing01

    SofaKing01 Master Member

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    Hey BK,

    We've been calling those the "Canopy Boxes". They have several levers and greeblies attached. They are VERY prominent in that shot, but we think the boxes we're removed and just the greeblies that were attached remained and adhered to the canopy itself. I love the look of the boxes and I already have them built. Just waiting for when the canopy is ready to accept them! :)
     
  44. SofaKing01

    SofaKing01 Master Member

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    Thanks, J! You always have a kind word to say! Much appreciate it!
     
  45. SofaKing01

    SofaKing01 Master Member

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    Hey T!

    Thank you so much! Shoot me a PM! :)
     
  46. SofaKing01

    SofaKing01 Master Member

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    AWESOME! Thanks K! :)
     
  47. Markas1976

    Markas1976 Well-Known Member

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    Brilliant work well done I don't have the machinery to pull this off mabye in a couple years though I might do I'm still a baby in prop making just 16 months so far even though I am 42 years old lol.
    I would love to tackle this cockpit plus a bit of corridor one day ur doing great pal
     
  48. SofaKing01

    SofaKing01 Master Member

    Trophy Points:
    3,660
    Hey M,

    Thanks so much for the kind words. :)

    I didn't have ANY of the tools I have today when I first started. All those LED holes I drilled by hand! It was a chore but I had so much fun! Its funny... the only thing stopping me from drilling all those holes was me. Now I have the laser cutter and/or the CNC. And if those go down? OH MAN! lol

    Whether your 42, 22 or 62... the fact that you're building something and having fun is MOST important. The more you build the more experience you gain. You'll begin to see all the shortcuts and find better ways to do things easier. But dont lose sight of the fun!

    Speaking of corridor... I'm always tinkering with the idea to build a portion of the corridor to simply attach to the existing cockpit. That would be SO MUCH FUN!
     
    Last edited: Dec 14, 2018
    greeble_gremlin and Mad Monkey like this.
  49. BruceKenobi

    BruceKenobi Active Member

    Trophy Points:
    361
    Hey SK! I just love the idea of overhead greeblies, levers and buttons, they remind me of DHC-6 Twin Otter that has the throttle on the overhead section and you accelerate with your hand up!! I hope you can post some photos when they are up!
     
  50. BruceKenobi

    BruceKenobi Active Member

    Trophy Points:
    361
    I'm putting together a video on all the cockpit shot of the falcon! I'll let you know when it's up
     
    Lt Washburn likes this.

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