Five Foot of Fun, ANH Style !

Discussion in 'Studio Scale Models' started by bwayne64, Mar 11, 2015.

  1. bwayne64

    bwayne64 Well-Known Member

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    Well thought I'd go ahead and build a Naked Falcon, ;) After the great thread by Andre and Maruska, I had to see how big this bird will actually be. I figure if it doesn't work out, I can always turn it upside down and make a bird bath, LOL. If I get it right, I can add detail as I buy kits. I started by making a 79.05 inch trammel to draw the curve of the hull. That would be one humongous sphere if you had the whole thing. I started thinking of all kinds of router jigs and such to carve the shape, but ended up putting on my sculpting hat. The only thing I hate more than sculpting, is painting , yuck ! Sorry about the picture quality, camera is old and on the fritz.

    Drawing and Mdf Template

    DSCF1327.JPG

    First I cut out a 1/8 th pie slice of foam. I was going to do a whole quarter at a time, but it was too much to bite at one time.

    Rough Wedge.jpg

    I used the Mdf template to draw the curve on the foam

    Rough Wedge Edge.jpg

    Got out the ole hacksaw blade and started wacking away anything that didn't look falconish, ;)

    Wedge Hacked.jpg

    After a few hours of hacking and sanding, cough, cough, I had this

    Wedge Shaped.jpg

    Here it is from the back

    Wedge Shaped 2.jpg

    Then I had to make another piece just like the first and glue them together. With the two 1/8 slices together I now had a 1/4 hull section.

    I couldn't get it perfect by hand, so I made a jig I call the "Blade". It's a scrap piece of 1/2 inch Mdf cut to the exact hull curve. I epoxied a piece of brass tube that can pivot on a bolt. I then glued on a strip of 100 grit sandpaper to the bottom of the "blade". By sweeping back and forth it sands the wedge to exact shape. It's hard to describe so here's some pics.

    Blade Side.jpg

    Blade Pivot.jpg

    Blade Foot.jpg

    Blade Back.jpg

    Now I'm just waiting for some resin and glass to harden up this puppy. Figure I'll glass it and pull a mold. Then I can cast up sections to piece together. I may end up making a half hull mold. I'll see how it works out. Should have my supplies in a week or so. To be continued........

    Cheers,

    Joe
     
    Last edited: Mar 11, 2015
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  2. bwayne64

    bwayne64 Well-Known Member

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    Oops, forget the required Coke can pic, it's diet but it's all I had, ;)

    Coke.jpg
     
  3. vfxsup64

    vfxsup64 Well-Known Member RPF PREMIUM MEMBER

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    Beautiful work! Looking forward to more...
     
  4. Vacformedhero

    Vacformedhero Sr Member

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    Brilliant, we have to see some 5 footers take of .
     
  5. bwayne64

    bwayne64 Well-Known Member

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    Coming from the King of beautiful work, that is high praise, ;) Thanks man, resin is on the way. Can't wait to get a mold going. It's all your fault you know, I wouldn't have even considered building this behemoth without all your work. Thanks man,

    Joe

    - - - Updated - - -


    That's funny, I actually did see a flying Falcon on YouTube the other day. Looks like we might have a fleet of these puppies soon. Cheers,

    Joe
     
  6. rbeach84

    rbeach84 Sr Member

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    BWayne, you are using a fabrication technique similar to using a 'scree'. Think of having your profile mounted on a central pivot post, with a huge gob of clay around it. By dragging the profile over the clay, you 'screed' out the shape then suitable for laying up a fiberglass mold. I like your method since it allows you to use a more rigid material less susceptible to temperature variations (clay is best handled when cold...but for workability when cold... you see the problem with that...)

    Nice job! I look forward to your further success! And I hope the 5-footer decal survey I'm participating in right now will be a resource for you when you get to that point in the project.

    Regards, Robert
     
  7. bwayne64

    bwayne64 Well-Known Member

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    Robert, yep, I actually saw this done in Cinefex magazine back in the 80s. They were using a sheet metal template, and plaster for the medium. I also use a similar technique in my 3d program. You make a cross section and lathe it on an axis. So nothing original here, besides my extreme laziness that is, LOL. If I would finish my CNC router, I wouldn't have to leave the shop office, except to set up the machine, and sanding the mill marks off the finished shape. Oh well, laziness is the mother of invention, or something like that, Cheers,

    Joe

    P.S. I so loved the decal sheet. Already saved it to the computer. Guys are coming out of the woodworks on the Big Falcon. Great time to be spending money and breathing carcinogens, LOL !
     
  8. rbeach84

    rbeach84 Sr Member

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    BWayne, stay tuned! Retiredadguy's 'decal sheet' is still a work in progress; expect that there will be some very accurate artwork and placement maps produced & shared here in the future! Of course, the 'InSitu' decals image archive could serve if anyone wanted to draw their own marking as well.

    One big challenge right now is how to convey the actual sizes of the decals. Retired and Imurme are both working on the relative scaling of those decals so once the model size is determined as a ratio of the 5-footer, the markings can also be scaled accordingly by the same ratio. So, if you're doing one of the 1/2 Studio Scale models (like the Hasbro 'toy'), you've got everything you need.

    Regards, Robert
     
  9. Vacformedhero

    Vacformedhero Sr Member

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    will anyone be producing these decal sheets as scaled decal sheets for each of the current millenniums in the works,hasbro, deagostini etc,
    or is there a way to turn these images into decals ?
    Sorry if this covered in another post
     
  10. rbeach84

    rbeach84 Sr Member

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    Vacformed, that is the plan... Retiredadguy has stated he is using his artwork to size for the Hasbro 28-inch MF. I recommend subscribing to the thread and keeping an eye on developments... Regards, Robert
     
  11. Vacformedhero

    Vacformedhero Sr Member

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    Thanks I had already but it wasn't clear what the game plan was, it mentioned sharing but not if it would be a actual decal sheet, cheers
     
  12. bwayne64

    bwayne64 Well-Known Member

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    Robert, I'm actually doing the big five footer, but I never even thought about decals until I saw your thread. I'm just building a naked falcon right now. One without details. Maybe later I'll be finishing it if I win the lottery, LOL. I've been buying kits for years for an SS Galactica. Still collecting for that project. Luckily there's some crossover on the kits used. I have bought two kits recently for the falcon. An Entex Mazda engine and the Airfix Pontoon bridge. I'll buy them off and on when I can. Maybe I'll get em both done before the Good Lord calls me home, LOL. Cheers,

    Joe
     
  13. bwayne64

    bwayne64 Well-Known Member

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    Well finally did a bit more work on the Nekkid Falcon. The pink foam is great stuff to sculpt but it also dents if you breath on it, LOL. So I needed to up armor it a bit. I made this Mdf frame to strengthen it and to give me some nice 90 degree angles on the side of the plug. There was no way I was going to get a straight edge on the foam, so ya do what ya gotta do. Here are some pics,

    Mdf Frame.jpg

    This kinda looks like a baseball diamond, :)

    Mdf Frame 2.jpg

    Mdf Frame 6.jpg

    Mdf Frame 4.jpg

    Mdf Frame 5.jpg

    Gluing in the foam core. Got a 3/8 steel top on the table, so I can use my handy 90 degree welding magnets here. Wanted to make sure I got a perfect 90 on the sides.

    Mdf Frame 7.jpg

    I also put an edge band of 1/16 Ply on the front edge . Strengthened it up quite a bit. Now just to fiberglass this beast and get it ready to mold, Yea !

    Mdf Frame 8.jpg

    Mdf Frame 9.jpg
     
    Last edited: Jun 13, 2015
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  14. bwayne64

    bwayne64 Well-Known Member

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    Now on to the messy part. Got my epoxy supplies a few weeks ago. I went with US Composites 635 thin epoxy with the medium hardener. US seems to have the best bang for the buck. Under a 100 dollars for almost a Gal and a half. Seems to work well, time will tell. Here we go,

    Here's the epoxy supplies,

    Epoxy.jpg

    Cutting the cloth for layup. 1 layer of 6 oz. 1 layer of 2 oz.

    Cutting Cloth.jpg

    Layed on the first layer dry for a looksie, ooh, shiny, ;)

    Cloth Dry 1.jpg

    Wet out.

    Wetted Out.jpg

    Wetted Out 2.jpg

    I'll try to post some more pics tomorrow of it trimmed and primed. Now I just need to make another piece of the pie to make a half shell plug. Don't want to have to lay up 8 shells for every hull. This thing has a real nice curve, thinking of making a big flying saucer out of these molds too, LOL. Better than the original bird bath idea, ;)


    PS. Attachments weren't showing up right on my end. They work if you click on them, but a few don't show thumbnails. Checked it several times, hopefully it's just on my end. Old decrepit computer, LOL * Fixed I hope ;)
     
    Last edited: Jun 14, 2015
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  15. Vacformedhero

    Vacformedhero Sr Member

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    Brilliant progress, I too have been trying to source a curve to mimic the 5 foot falcon, I did look at bird baths too but the closest I've seen are convex mirrors, especially the types used on public roads ( for Americans with your wide roads that may not make sense but we have some roads the width of the car Door mirrors and we travel at speed so a lot of tight garden exits need these mirrors)
    anyway , Wayne are you doing this curve by eye? It looks fantastic,
     
  16. Jaitea

    Jaitea Master Member

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    Great thread,....so cool
    J
     
  17. bwayne64

    bwayne64 Well-Known Member

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    Actually I made a trammel, basically a giant compass to the dimensions from the Andre and Maruska plans.

    http://www.therpf.com/showthread.php?t=199048

    Once I had the curve I made a template to sand the foam. There's still a lot of handwork to get it right. It is always surprising how hard a simple shape can be to get perfect. It's looking pretty good now. Good enough for gov'ment work, as they say. Thanks for the kind words, cheers,

    Joe

    - - - Updated - - -

    Thanks Man, its been fun doing this one, cheers,

    Joe
     
    Last edited: Jun 14, 2015
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  18. GlazyUK

    GlazyUK Active Member

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    Five Foot of Fun, ANH Style ! I was hoping it would be Princess Leia ! :(

    Still great work so far !!!
     
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  19. bwayne64

    bwayne64 Well-Known Member

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    Yea as long as we're talking Anh through Jedi , Leia, ;) Thanks man, I'm having fun so far. Cheers,

    Joe
     
  20. eagle1

    eagle1 Sr Member RPF PREMIUM MEMBER

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    Looking great Joe!. Its interesting to see how we all approach the hull in different ways. Your method looks sound & will look great!.
    I'm going now with a half section wooden buck & have vacformed in 3mm styrene. Still deciding on whether to laminate two 3mm sections together to get the 6mm hull thickness or just tweak things a bit.
    Stu
     
  21. bwayne64

    bwayne64 Well-Known Member

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    Thanks Man ! I'm actually debating the vac form route too. Great minds, LOL. I know I can lay up the parts in a mold, but styrene would be so much faster and easier. The only problem I have is building the big honkin' Vac former. A half hull will be about 25 by 50 inches. That's a big piece of plastic. If you have enough vacuum you could probably pull the 6mm sheet and forgo the lamination. Any pro vac form company should be able to do that with little problem. Please post the result when you get it done. It will help me to decide which way to go. I know fiberglass pretty well, that's why I went this route. This is only the pattern right now. I made it oversize so I have the option to vac it. We'll see which way is best. It would definitely be easier if one was going to sell a few copies, Not that I am, ;) Cheers,

    Joe
     
  22. bwayne64

    bwayne64 Well-Known Member

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    Sorry it took a few days longer to get these pics done. Finally got the 1/4 slice trimmed and primed. There were a few shallow spots here and there. Had to get out the ole spot filler. It doesn't matter how careful you are, there's always a few high and low spots. Even if I Cnc'd this thing, you'd still have mill marks to contend with. So here's a few more pics, Enjoy.


    Filler.jpg

    Filler 2.jpg

    Filler 3.jpg

    After a few coats of filler primer, filled in the low spots with Filler putty.

    Spackle.JPG

    Spackle 2.JPG

    Another primer coat, then hit it with a little drywall spackle compound. I like to use this to fill small spots in primer. It sands great, and filled those little spots easier.

    Primer.jpg

    Primer 2.jpg

    The last few primer coats. I think I'm close now. Still want to throw on a black guide coat, to check for any sneaky spots that I may not see with my poor eyes, ;) Then it's on to making the other half of this thing, Argg !

    Dome Comp Final.jpg

    Couldn't wait to see what a full dome will look like. Threw a pic together in Photoshop to get a sneak peek.

    Now on to making another quarter dome. Got a few tricks for this. Don't want to go through the same hassles for a new section. Stay tuned, Cheers,

    Joe
     
    Last edited: Jun 17, 2015
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  23. Tom1971

    Tom1971 Sr Member

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    Looking awesome!!!!!!!!!!!!

    Very exciting to watch!!

    Tom
     
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  24. joberg

    joberg Master Member

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    Well, you had me at "5 foot of fun":rolleyes...seriously, I'll be glued to your WIP like crazy!
     
  25. bwayne64

    bwayne64 Well-Known Member

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    Thanks Guys,
    I'm enjoying this cause it's in my wheelhouse. Been working with messy fiberglass for a long time. I hate the mess, but love seeing a shape that was on paper or the computer become real. And who doesn't love the Falcon. Cheers,

    Joe
     
  26. Bondo Fett

    Bondo Fett Active Member

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    So excited for this project. Love glassing over foam, its such a fast and versatile method, and works great at almost any scale. What primer/surfacer do you use? Do you get have any problems with epoxy blush?
     
  27. bwayne64

    bwayne64 Well-Known Member

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    Hey man, haven't had any so far with this epoxy. If you ever do just wash it off with a fine scotch brite pad and water. Blush is water soluble so it comes right off. Don't use acetone as some people have, not me of course ;). I'm using rustoleum filler primer on this as I had some laying around, and it's cheap, LOL. This is just the plug so as long as I can get a smooth surface it will be fine. I'll use a molding gelcoat on the mold so I can get a lot of pulls from it. The plug just has to last through molding. I also like the foam method. I just need a cnc router so I don't have to carve the shapes by hand. I'm a lousy sculptor. This is a fairly simple shape, but it still kicked my butt, :) Cheers,

    Joe
     
  28. rbeach84

    rbeach84 Sr Member

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    Funny, it doesn't look like a boot!

    Great guns, mate!
    R/ Robert
     
  29. bwayne64

    bwayne64 Well-Known Member

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    LOL, sure felt like one, ;) Luckily I think I kicked it back. I put on a semi gloss black guide coat, and except for a few very small imperfections it looks pretty smooth. Now onto making another side and then molding. Stay tuned for more fun with the five footer, Cheers,

    Joe
     
  30. SofaKing01

    SofaKing01 Master Member

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    EXCELLENT WORK! Not too late to back out and make the Enterprise! GASP! Did I just say that? ;)
     
  31. rbeach84

    rbeach84 Sr Member

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    I wonder what would happen if we replaced the Enterprise's saucer with a Millennium Falcon? Would the universe implode?

    R/ Robert
     
  32. Axlotl

    Axlotl Master Member

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  33. bwayne64

    bwayne64 Well-Known Member

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    Oh don't tempt me. I have prints of the 8 foot refit. Can't do that one yet. Too many irons on the fire, and not enough in my blood, LOL.

    Oh by the way, love your cockpit project. That thing is smokin' ! Would love to sit in that thing someday. When you finish it, you should bolt it to a flight sim gimbal and charge admission, ;)

    - - - Updated - - -

    Couldn't be worse than the JJprise ;)
     
    Last edited: Jun 26, 2015
  34. Star Lord

    Star Lord New Member

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    Any progress on your build? I've just discovered this thread and am really enjoying your efforts thus far. You guys make this stuff look easy!
     
  35. bwayne64

    bwayne64 Well-Known Member

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    Had to wait on a few materials but ready to get back at it soon. It's been 100 degrees plus in the shop for a while now. Humid and muggy. Trying to do a little here and there at night. Hope to have an update soon. Thanks for watching, Cheers,

    Joe
     
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  36. SofaKing01

    SofaKing01 Master Member

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    As you said... Dont tempt me! If I won the lottery I'd recreate the entire Hoth Hanger! And maybe even a ATAT or two. ;)
     
  37. bwayne64

    bwayne64 Well-Known Member

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    Well here's hopin' you win that sucker. A Hoth hanger would be awesome ! Or a bay 94. As hot as its been here I think I'm leaning toward the Hoth bay, ;)
     
  38. SofaKing01

    SofaKing01 Master Member

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    AMEN! :)
     

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