I have been working on the rear hatch lately. This is one part that has always perplexed me; I've never been quite sure how it was made. So, I looked at as many photos as I could, took some time to think about it, did a few trials and this is the method I have come up with.
There has been some
discussion about whether the middle of the impressed part of the cone is flat or domed. I agree that it is subtly domed, based on what I've seen in pictures. However, this could always be chalked up to lens distortion.
The main proof came from
these pictures of parts apparently out of the original molds from ANH. This is the only internal view of the rear hatch I have ever seen:
A few things jumped out at me. The first obviously being the concave surface.The second thing is the putty around the window, which appears to have been put in before the window was cut out. So I suspect this was a feature of the master and not some funky molding technique. But, hey, I could be very wrong. Finally, there's the really sharp brim to this piece. Not like any of the other hatches.
So here's my best interpretation of how this component was made.
I made a couple of cone bucks in Blender and 3D printed them to make a vacuum-forming buck (I can give you my STLs if you want). The following series of images are not really chronological and reflect a few different attempts at this.
Then I trimmed out the cone with a height gauge:
This would form the outer cone, which I then welded down to a dome that I vacuum-formed over my 5.25" hemidomes:
To make the inner concavity, I felt from looking at images this surface may have been a bit concave, rather than conic, so I formed some 1.5mm styrene over a 2.75" hemisphere, then cut and sanded it down to the "right" diameters.
This all fits together near-perfectly:
Add another dome over the middle and the rosette of chips:
I think the chips should taper inwards a bit; mine are probably a bit too parallel-sided. If I had thought it through a bit better, I would have formed them over the 2.75" hemisphere, too (perhaps immediately over the 1.5 mm pull). But here we are.
And here's the near-finished product:
Far from perfect, but happy enough with the result for now. I've learned a good few things that I would do differently if I were to do it all again. Overall, the process seems to work, but did require a good bit of puttying and sanding at the contact between the outer cone and the underlying dome. I don't want to do it again, but now when I look at it all I see are the imperfections!
And, of course, in a nod to the original, I puttied the back:
Not really functional in my case, but does thicken out the window frame a bit, so why not.