Han Solo in Carbonite Replica

Very nice HIC indeed, I'm sure you're well-chuffed with it Keith :)

I have finished fiberglassing the inside of the dash panels, so those are nice and strong now and won't warp. Next job is to fit threaded rods inside the panels and drill holes in the HIC block which line up with the rods, so the panels can be fitted and removed when needed.

Now that's one hella good idea mate! Are you using original Volvo dash panels, or resin casts of Volvo panels?
I've got resin cast Volvo panels, and it didn't occur to me that the resin might warp over time. Can I ask you to post a couple of pics of your fibreglassed side panels' rears?

I would've worried that the heat generated by the GRP 'going off' / curing, would distort the resin panels - did you need to hold a cold, damp cloth on the outside of each panel to cool it down as the fibreglass cured?

Excellent idea with the threaded rods as well. I was gonna just use a 2-part epoxy glue to permenently bond them onto the HIC block. But I was a wee bit worried that I might get some of the glue 'bubbling out' the side of the panels, and looking messy :unsure
But I reckon the threaded rods and bolts could be a solution.... you're obviously using your years of trooper aerator mounting expertise, to come up with this nut 'n' bolt solution?! ;)

Cheers,
John
john@manicminer.plus.com
 
I'll try and get some photos tomorrow John if i get chance.

I'm also using resin cast Volvo panels.

I cut out a card template that fitted on the inside of the panel, along the "roof" and down the sides when folded at each end. I then used that to draw around in pen on the fiberglass matt and cut out 16 of them in fiberglass matt.

I then coated the roof and sides of the inside of the panel with resin using a brush, laid the cut to shape fiberglass matt in place, then using the brush again, coated the matt with more resin.
To avoid any heat from the setting resin, i let this one layer fully set and there was no heat generated at all from the resin. I did this on all 8 panels.

I then sanded any sticky up strands of fiberglass away and added a second cut to shape fiberglass matt section using the same process as above to all 8 panels. This is why i cut out 16 of them in fiberglass matt.

With the fiberglass matt being one piece thats cut to shape, you end up with a nice and tidy fiberglass job.

I wouldn't glue the panels on John. You might need to remove them for some reason in the future.

Keith.
 
Cool... thanks for the mini-tutorial, Keith :thumbsup

I've just received my Hero Panel electronics, so now would be a good time for me to 'beef up' the insides of my HIC's panels.

Have you got any pics to share plz mate?

Cheers,
John
john@manicminer.plus.com
 
Very clean. This will make for an impressive display. I started one from scratch about 15 years ago and never got anywhere with it. Great work.
 
Here are the photos of the panels for you John. The blue stains in the fiberglass is just ink from the pen i used to draw around the template on the fiberglass matt.:







Keith.
 
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This looks so much better than the upcoming Sideshow one too. Not happy with that one, but we know its not a "replica" its a statue
 
Thanks!

I must say i really do love this replica. Even though its just in primer grey, i'm always finding myself just sitting there looking at it and thinking how cool it is.
Hats off to Neil for making it.

Keith.
 
Not finished it yet.
I will be painting it soon now the weather is getting better and warmer.
I have to paint it outside you see and i just didn't get time to get it ready for painting before the winter weather set in last year. I should have got the panels finished though, but didn't. I still need more stuff to finish the panels. I think i've spent more on the panels than i did on the HIC casting.

Keith.
 
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