The Barbican - My Build

[redbutton]

Today's build involved making the 'D' ring holder on the emitter. I cut and milled the clip with a Dremel and hand files out of aluminum. Next drilling a hole and a slot for the 'D' on the side, after that we, Tom and I drilled two open holes on the top the clip. Next came the holes in the emitter which we tapped for 6/32 bolts. One tip I used is that I put a tooth pick under the 'D' ring to help steady it. All and all a good prop day!

 

[lesternessman]

Nice!

 

[Benjo]

this thread definitely ROCKS <3

 

[thd9791]

We had basically half inch bar stock in our metal box and that appears to be the real height it is so awkward it pokes up a bit over the shroud…. On the real prop

Width and length we calculated but I thought that detail would be interesting

 

[eethan]

yes it pokes up a bit on the real prop! weird thing though, they actually rounded the bottom for a perfect fit on the shroud!

both front angles of that clip also have round corners

 

[thd9791]

yes it pokes up a bit on the real prop! weird thing though, they actually rounded the bottom for a perfect fit on the shroud!
View attachment 1614172

both front angles of that clip also have round corners

maybe we should do that......

thank you!!!

I didn't check, we're going to need a plug for the bottom... message redbutton we might be able to get you a diameter and pay you extra

 

[redbutton]

yes it pokes up a bit on the real prop! weird thing though, they actually rounded the bottom for a perfect fit on the shroud!
View attachment 1614172

both front angles of that clip also have round corners

Yes, yes I see it - more carving to do, THANKS!

 

[Halliwax]

Looking good man

 

[redbutton]

Well, I, we rounded the bottom of the D ring clip sculpted the front
of the clip too. Next up was the primer (auto) on the emitted then painting
with two coats of black over that - I also painted the bars just behind the clamp. I also cleaned up the mystery part just behind the emitted. We drilled holes and tapped for the tiny brass screw the hold the greeble on the main tube. We also drilled for the holes just behind the emitter also on the main tube. more to come....

 

[Halliwax]

Looks great buddy

 

[thd9791]

Thanks!

Yea, for more context, we hit a few snags and had to work around them.

I bit the bullet and experimented with my stunt saber first. I ran a 0-80 tap into all of the grips on the stunt saber. (Glued them down with clear loctite first) and I only needed like.. 1/4 inch screws or something. The greeblie up top is thicker... so when we got to the Barbican build, we had to switch to long screws, and redbutton here tapped those holes. The greeblie itself we cleaned up with a dremel and hacksaw, pretty straightforward, cutting off the excess material and drilling out the holes that i filled with clay when making the mold. I specifically squish clay deeper into holes so you can see the rim of the hole in each pull, for cleanup later.

Again, I used my stunt saber as the experiment with the countersunk bolts, so we just matched the x and y measurements to find the holes on the Barbican tube. Since we weren't using a core on this one (not counting the solid plug added in later) we started with a random drill bit and bored them out with zero-flute bits until an M6 bolt head could sit inside.

Paint.. gotta hand it to Halliwax here. We started with black rustoleum automotive primer... hit it with 400 grit sand paper... then used the infamous tall "professional" rustoleum flat black spray paint. Dusted it on (outside) in 2 or 3 coats over the emitters and the TCSS clamp sidebars. A heat gun and 24 hours seemed to do the trick, we rubbed it with coffee filters to shine them up a little.

The screws I found are also used on model trains, for what it's worth.

 

[Benjo]

it takes barbican/stunt replicating to another level. These two replicas are just like the real deal. I very much prefer the square shroud version with longer grips but weren't they smaller during ANH/ESB, to match the ANH setting?

 

[thd9791]

it takes barbican/stunt replicating to another level. These two replicas are just like the real deal. I very much prefer the square shroud version with longer grips but weren't they smaller during ANH/ESB, to match the ANH setting?

Thank you!

You’re correct, the clamp even sat lower in ANH. Given the way the other props were handled, it’s my best guess that the grips they screwed down weren’t an end detail, but something from filming empire. I think I see foam grips in the famous shot on screen but the Vader hand gag retained the bolts, t track greeblie and bubbles from empire, so I take it the grips are from then too.

It seems the most obvious thing, the square shroud, was cut down and a greeblie was added to it, and the short core was glued in place for the mold.

The end cap plug, circuit board and new D ring block were after filming add ons.

I still can’t tell when the mystery part was added, since it’s screwed down with the same screws as the grips. I already found a part from the DV6 in empire so what are the chances this black part is from then too?

 

[Benjo]

Thank you!

You’re correct, the clamp even sat lower in ANH. Given the way the other props were handled, it’s my best guess that the grips they screwed down weren’t an end detail, but something from filming empire. I think I see foam grips in the famous shot on screen but the Vader hand gag retained the bolts, t track greeblie and bubbles from empire, so I take it the grips are from then too.

It seems the most obvious thing, the square shroud, was cut down and a greeblie was added to it, and the short core was glued in place for the mold.

The end cap plug, circuit board and new D ring block were after filming add ons.

I still can’t tell when the mystery part was added, since it’s screwed down with the same screws as the grips. I already found a part from the DV6 in empire so what are the chances this black part is from then t

Well spotted. I Think you're damn right !

 

[redbutton]

Updates to my Barbican...I cut a card for the clamp, from a head board also, made a aluminum blank for the inside of the emitter and we tapped it for 1/4 20 for machining on a drill press. I painted the black caps and glued them in the holes. I have a really casting of the mystery part next to the emitter. Will be putting screws

on the grips soon.

 

[thd9791]

This looks so cool with the card and holes capped!

The core was.. what, 1-3/8 aluminum round cut to whatever the height was from the top of the tube to the middle of the upper holes. We found the center and ran a 1/4 20 tap through it so we could spin it in a drill press and sand it to fit

A wooden mallet finished the job

 

[Psab keel]

I love this build!

 

[thd9791]

Oh, I should say I have a mold of these caps.

Message me for the source of the caps, but there’s a stupid minimum order, and if you only want a few, I have perfect resin casts

 

[redbutton]

Howdy, I finally finish my barbican! Here's some beauty shots. Thanks to all the people who helped cast and mold as well as lathed parts!

 

[thd9791]

The endcap fits like a glove! Looks just like the real prop, it’s uncanny

I think going through the process of cutting all the aluminum hand made parts makes this super special