One more Han In Carbonite

[mattycsi]

I always wanted one of these, and managed to pick up an off cast of Han parts in the JY a couple of years back.

When the parts arrived they were pretty beat up, as you'll see.

This was just to do a front panel, I don't really have a whole lot of space for him so it would be a waste to do the full box. Also cost is a factor, I can retro fit the rest later if cash/space/time allow.

First off, built the frame and laid him out.


Then to fully inpect the damage.

Right leg broken off.


Left knee broken.


Right hand sheared off from the body.


Head off.



totally knacked.



His back wasn't flat, rather bevelled and concave. I screwed and grab adhesived some blocks on there to level him out.



Fibre glassed his legs back together.



Glued and filled hands together.



Glued him and screwed onto the frame. Grab adhesive on the parts that met the board and screwed through from the back into the blocks. He is solid resin so I managed to carefully get a few screws into him too.


There was some rather large gaps under him so I filled it with expanding foam. And filled a few dings in him.


Carved the foam off his sides and started filling/sanding the joints of his reconnected bits.



Coated the frame in filler and put a load over the foam to smooth it off a bit.



Lots of sanding and a dose of primer.



Masked him off and sprayed the frame. Used Halfords steel wheel trim paint and gloss clear coat.



Then began layering up the carbonite. I used builders PVA and just kept adding layers once it skinned up tough. It took a few weeks in all, but wasn't in a rush over Christmas.




Once it was all dry I masked off the frame and painted him and the carbonite. This was Halfords Silver wheel trim paint. A blackwash all over and then sealed with a light coat of clear gloss.

 

[silkscreener]

Looking good. Had no idea you could get parts like that and fix them how you want.

 

[QCWolf]

You did a great job with what you had to start with. Nice work!

 

[mattycsi]

Thanks guys.

Looking good. Had no idea you could get parts like that and fix them how you want.

These were someones first go at casting I think. Which is why they were in such bad shape. It was supposed to be one piece. But I knew what I was getting and it was priced accordingly.

You did a great job with what you had to start with. Nice work!

I had problems with the joins of the broken parts kept opening up, I don't know whether it was he wood expanding/contracting with the temperature changes. I pushed some plumbers mait into the cracks and that seemed to do the job (read that tip on here somewhere, can't remember who or would credit it).

 

[QCWolf]

I had good luck with Bondo.