Han in Carbonite "box" research?...Update post#45!

darthwhitey

Sr Member
RPF PREMIUM MEMBER
hey guys,

It seems like the life-size Han in Carbonite is a "grail" prop for many of us.

There have been a few runs of the front panel with Han making the funny face. There have been runs of the side panels. But to my knowledge, we have limited access to a good source for the "box" that is so important for an accurate HIC.

One option is cutting one out yourself. But most of us have no tools (or no time) to do this properly. Even if you have the tools, you'll miss out on some of the accuracy the piece requires.

The best way to cut the box is with a CNC (Computer Numerical Control) router.

I picked up HIC plans from a gracious member here on the RPF that seem to be very accurate. I've sent these plans to TWO different CNC machine shops here in the USA inquiring about a "run" of these. It seems to be very doable, and not crazy expensive either.

Obviously, we all want this to be as screen accurate as possible.

I'm willing to do the legwork on these if I can get a little help from those that have done them in the past, or especially those that have used these plans.

1. Is it cool that I post the plans in this thread?

2. The box could be machined in 1/2" or 3/4" MDF board. I think 1/2" makes sense to cut down on weight?

3. After sending the plans to the CNC shops, they asked if it's available in "CAD." They said if it's not they can draw it up, but that will raise the price a bit.

4. Here is another comment, these guys are serious and accurate!...:)

"Also I see there are pockets that run at an angle in the depths Section A-A. So this part has to be tipped up at an angle so the machine can cut flat bottom pockets and the will be angled when complete. This will require a fixture of some kind to hold it at an angle. This will make machining more difficult."

So...that's the deal. I think if we can get together a decent number of guys interested it will help drive costs even lower.

I have all the same questions you do. How much is shipping? How do we assemble it? How do we patch seams? etc etc

The honest answer is...I don't know. I'm more than willing to do the first one for myself and be the guinea pig, with help from you guys. Then we could gauge interest after that...??

Bottom line. I'm here to get a HIC myself, not make a bunch of money on a "run." I'm still in the planning stages of this and need your help and advice. I'm going to set out to make as accurate a "box" as I can while still being practical.

I've attached a pic of an HIC made by member "Vos" who has used these plans with success. (I hope that's OK) This is how good this thing can look! :love

I'd love to hear your feedback and suggestions, comments or concerns.

thanks!

brad
 
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re: Han in Carbonite "box" research?

Pm sent. Is that using a Han StormRider casting and if so which one. Pieces or to the edge version?
 
re: Han in Carbonite "box" research?

Amish Trooper,

The front panel I have is a "VashDstampede" all one piece casting. I think it's fiberglass?

It's been sitting in my garage forever! :lol

I'm excited to get moving on it!

thanks for the interest!

brad
 
re: Han in Carbonite "box" research?

Jeez Brad, I think a box in kit form would make a lot of people happy. Sounds very promising ...
 
re: Han in Carbonite "box" research?

You could count me in for one.
Like so many others I assume, I have had my front 'face' panel sitting at the shop collecting dust for several years.
It's way past due for completion!
 
re: Han in Carbonite "box" research?

Hi everybody - just chiming in

I have a CNC machine and it all looks doable except for the hands - most CNC machines can't do under cuts like those hands would require - so I'd double check with your shops that they can do those hands like your picture shows
 
re: Han in Carbonite "box" research?

Hi everybody - just chiming in

I have a CNC machine and it all looks doable except for the hands - most CNC machines can't do under cuts like those hands would require - so I'd double check with your shops that they can do those hands like your picture shows

The Han in the picture is a separate piece. That isn't what would be CNC'd he is referring the the actual box. Side panels
 
re: Han in Carbonite "box" research?

We're focusing on the actual 'box' part of the prop, the carbonite 'sludge' with Han's body cast is sometimes referred to as the 'face' panel.
I am hoping a kit of the box can finally get off the ground. I have seen far too many failed attempts or empty promises over the years...
 
re: Han in Carbonite "box" research?

Ah sorry - my bad I thought y'all were CNCing the whole thing... I'd offer to help make the box but my machine is only 4' long so I wouldn't be able to do the long sides
 
re: Han in Carbonite "box" research?

We're focusing on the actual 'box' part of the prop, the carbonite 'sludge' with Han's body cast is sometimes referred to as the 'face' panel.
I am hoping a kit of the box can finally get off the ground. I have seen far too many failed attempts or empty promises over the years...

I'm hoping this gets off the ground too...:)

Here are the plans I sent the shops...

brad
 
re: Han in Carbonite "box" research?

Here's a *slightly* OT question... What is the origin of the angled plans?

The reason I ask is because I have heard from two different camps and one is steadfast in it's belief that the box is square and the other is convinced that it's angled.

From the screen shots I've seen it looks square (notice you can't see any of the sides in this straight on shot):

han-solo-carbonite-blanket.jpg


I'm hoping someone with more research into the actual prop has the answer for me as I'm just starting to work on this now and I have the same plans that Darthwitey has.
 
re: Han in Carbonite "box" research?

This would be great, price not withstanding. I like the box version myself, as the angled version seems more challenging to build.
 
re: Han in Carbonite "box" research?

Looks angled to me..

Good luck with the project mate. :) If you need a hand just shout.

Neil
 
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re: Han in Carbonite "box" research?

I can do the CAD. han in rubber has been chilling on my pool table for a couple months now...

37370_633063398863_15203089_35609783_6041810_n.jpg


I was lazily looking for the plans to take over to my friend who owns a cabinet shop. we'll see whats easier for me. either way i'll do the CAD drawing from those plans. it wont take long once i sit down and start it.
 
re: Han in Carbonite "box" research?

A box in kit form is a great idea and I hope this gets off the ground. I always thought it was angled myself, probably because of growing up with the toy.
 
re: Han in Carbonite "box" research?

Orange Blend,

Yeah, I kinda wish it was square...:lol Sure would make things easier.

I've attached another photo that another member posted. It seems to be of an actual HIC from Lucas Archives. It looks angled too.

Vos,

Thanks, your HIC is coming along nicely. I'm most impressed with the super smooth surface you've achieved and the total lack of any seams. I'll be reaching out to you for sure! thanks you! :thumbsup

zenix,

CAD drawings. That's awesome! I think that would save some $$ on the project for sure. thanks!
 

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re: Han in Carbonite "box" research?

Here are a couple more thoughts...

Some of us have a "full" front panel (or at least a full panel cut in sections) and others have the rubber partial "cut out" panel (shown in zenix's pool table shot) that was offered here recently.

From how I understand the plans, it shows a top "frame" made out of wood, not a solid wood top.

This should be fine for those of us with a full front panel, but the guys with the rubber "cut out" Han need something to attach their rubber piece to. For these guys I think the whole top panel needs to be wood. I don't see a problem wih this, but it needs to be part of the discussion.

For those of us with a full front panel, I think the addition of a top piece of solid wood would just add to the overall weight and it's probably not needed...??

thanks

brad
 
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