1:1 Millennium Falcon Cockpit Replica - Group Build

[SofaKing01]

Just a thought... but will the grooved MDF bend the other way? so its smooth side out??
Just thinking it would mean you can use the grooves to fill with glue/resin to hold the shape & leave you with much less work to fill & smooth the outer surface.

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.

 

[SofaKing01]

Regarding the console, I've see very similarly shaped consoles in other places. I don't have any pictures though. I'll try looking around though.

Thanks, LtW! Any help is ALWAYS appreciated!

 

[SofaKing01]

I don't get on here as much as I'd like. So I see besides the 1:1 scale, you are doing two other smaller scales as well right. So whats the plan for those?
Sure are doing a great job on it all.

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.

 

[SofaKing01]

Yep, the MF cockpit windows look much better with double the trim! MDF is easy to bend...1) you can do thicker saw lines and it'll bend more easily than smaller one and you can reverse it and have the nice side up. Do glue a thin sheet of wood or plastic, set it for 24 hours and it'll hold the form you want.

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.

 

[SofaKing01]

That’s definitely one large cup of coffee, sure to keep you awake on your build

I haven't slept in 4 days!

 

[JediMichael]

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.

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.

 

[SofaKing01]

Hi Gang,

Part III - The Vertical Beams

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

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

Edges cut

Love it!

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

Added the interior trim

Making sure it still fits!

Filler

Same process for the upper beam

Part IV Below

 

[SofaKing01]

Part IV - The Vertical Beams (Cont'd)

Lots and lots of filler

Primer!

MMMMM Primer

The outer edges of the beams are perfect!

Han's side

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

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

What the heck... Part V Below!

 

[SofaKing01]

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

The tape acts as a template

Remove the tape and adhere to the styrene

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

Adhered into place

Trimmed the excess

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

I continued the process

Filler!

Vertical beams slowly coming along

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

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

And this is where we are!

Part VI - Coming!

 

[SofaKing01]

Hi Gang,

Time for Part VI

I designed and laser cut these odd looking shapes

I sanded and put them together

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

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

Part VII Below

 

[SofaKing01]

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?

A new corridor ring!

I laser cut these VERY thin trim pieces

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

Choo Choo

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

Interior supports

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

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

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

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

PERFECT!

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

I cut all the holes for potential wiring

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

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

More to Follow!

 

[Hostamon]

This is an UNBELIEVABLE FIND! I KNOW you had the "AAAAAAA" moment as we all do when finding that real world part. Now... Are there any out there?

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!

 

[SofaKing01]

Hi Gang,

Time for Part VIII - A Familiar Shape

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

Interior supports

Panel

Gee that looks familiar...

Acrylic details and panel faces

I laser cut this acrylic mess

Tough to see the basic shape

Another greeblie

Primer!

Part IX Below

 

[SofaKing01]

Part IX!

That's better...

More panels

Over 10" tall

And this is where we are...

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!

 

[IzzyMel]

Loving all the detail that you are putting into this

 

[Mad Monkey]

That laser cutter must be a God send!

 

[SofaKing01]

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!

Made sure the glass mat fit with the pencil lines

Mixed the resin

Now we wait for the resin to "begin" to cure

I laid wax / parchment paper across the cockpit

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

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

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

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

Nice!

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

Part II - Below

 

[SofaKing01]

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

Some styrene options as well

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

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

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

Top layer of MDF has the look of the corrugated mat

Tight fit!

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

Part III Coming! Stay Tuned!

 

[Lt Washburn]

Great work!

 

[DesertDan]

Just finished all 209 pages, absolutely amazing!