1:1 Millennium Falcon Cockpit Replica - Group Build

I do a lot of remodel work during my slow season in the HVAC industry, and NOTHING makes me want to just pack it up and go home like someone asking "How long do you think it will take?"

Now, I know as a customer they are just trying to get an idea of how long their house is going to be in disarray, and as a professional I never let on that it's like a kick in the nuts answering that question, but in my mind all I hear is "Well ****... Now I can go ahead an double my original time estimate" simply because they made me say it out loud. Happens every time.

Every.............single.............time.

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Hey ST,

When I'm at a con or event that question is asked all day / every day. I'm of the mindset that while I may have answered that very question 1 million times, that one person is asking it for the first time. Its the self imposed goals that BUG ME! ;)

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Hang in there bro, things will turn around for you man. I think i could probably speak for everyone, but I am positive this community is always here to support you!

Thank you, my friend! This forum is the best! :)

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I'm sure many here would be glad to lend a hand if we only lived within a reasonable distance of your build space.

Hey S,

I would appreciate any help form any and everybody! I can pay with pizza, drinks and lots of antacids! ;)
 
I drop in about once a month to check your progress, WOW. I get tingly inside when I see this!

Take your time and hopefully let it be a stress reducer and not a stress generator.

I saw your note on doing HVAC work. I used to be in HVAC for off road vehicles ( hint a big Green tractor company). Which raises the question, will this cockpit be air conditioned? ;)

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Hey TM,

Thanks so much! I'm hoping the tingle meter goes up these next few weeks!

We've considered using a sort of A/C but we're hoping that simple fans strategically placed will be enough. Surprising, even with canopy in place sans plexiglass, the heat generated in that small confined area is overwhelming!
 
This was a great update. Really cool that you've found a method of making those pads that you're happy with. It's still very different than what I imagine, but so long as they look right, it'll work. And they already look great in this mid-process version. This just makes it all the more necessary for you to do more of the corridor!

Hey LT W,

Thanks! I'm SO GLAD to have finally knocked out the pads. They bugged me for so long - how do I do them, what do I use, etc etc etc... Dang it, Man... stop thinking, just do it and knock them out!

I think you're right, so long as they look screen accurate and pass the "visual" inspection I dont think it should matter how its done. PLUS, they are really light weight and take up very little floor space when transporting.

More corridor? ok. ;)
 
It's good to see the pads. I'm thinking Chewie uses them like towels to wipe his wet fur on, explaining how they all turned from white to dirty yellowish. :)

LOL! I have two dogs and they use the weirdest things to scratch themselves with... the brick face of the fireplace, the bed frame or the cabinet edges. I can only imagine Chewie scratching his back or his face making those typical dog grunts and sounds!

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Great update SK -very inventive approach on the pads. I think they're looking good.

Thank you, my friend! I think they look the part. Once the paint goes on we'll know for sure. But if they turn out like the door pads we're in business!
 
Nice update indeed, can’t wait to see some colour on them, Alain the 1/4 scale cockpit is looking mighty fine

Thanks, B! I've already started the paint process on the test pad - pics coming!

The 1:4 scale is coming along slowly. I've had to go back and change a LOT of the framing to make sure everything fits the way its supposed to. I'm trying to mirror the 1:4 and 1:1 against each other. I'm really excited to see her put together. It will be about 50-55 inches long.
 
Do you have your own laser cutting or CNC equipment? If not, where does one go to get this kind of service?

Scott

Hi S,

We were fortunate to find a 53 inch by 33 inch laser cutter! She's an absolute beast. Also, we have access to a 5 foot by 9 foot CNC machine at a local Fabrication Lab. The new lab also a high end metal lathe, 3D printers, etc.

I would suggest looking in your area for a fabrication lab that offers 3D print services. They might offer more and or point you in the right direction. Hope this helps?
 
Really? I like them! I'm going to create an alternate yellow seat pad seat to mix things up! ;)

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I'm not convinced either. I'm thinking Han wins a YT, but its not the one he thinks. At least I hope Lando pulls the ol "switch-a-roo" on him!

Damn. Star Wars show and new TV spot mentioned it as THE Falcon. Still hoping we’re right!


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Sofaking01,

Started to print the Cowl files that Stinson created for the NAV chair.

Here are the internal frame pieces attached to the base of the cowl, still need one more part:

Internal frame for cowl by Izzy Mel, on Flickr

Internal frame for cowl by Izzy Mel, on Flickr

Internal frame for cowl by Izzy Mel, on Flickr

Would have had the sides done left in the morning with it going strong:

Untitled by Izzy Mel, on Flickr

But I came home to spaghetti..... UGH!!!!

only completed half of it. 25 hrs down the tubes. Oh well back to the drawing board the next time I will print one side at a time. The part looks great. to bad it didn't finish.

Untitled by Izzy Mel, on Flickr
 
Damn. Star Wars show and new TV spot mentioned it as THE Falcon. Still hoping we’re right!
Sent from my iPhone using Tapatalk

WOW! Really? hmmmmm... We'll know when we know. :)

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Sofaking01,

Started to print the Cowl files that Stinson created for the NAV chair.

Here are the internal frame pieces attached to the base of the cowl, still need one more part:

https://farm1.staticflickr.com/940/39761482280_da79897343_c.jpgInternal frame for cowl by Izzy Mel, on Flickr

https://farm1.staticflickr.com/868/41528821672_e398cac4a6_c.jpgInternal frame for cowl by Izzy Mel, on Flickr

https://farm1.staticflickr.com/932/26701439057_479248f3f9_c.jpgInternal frame for cowl by Izzy Mel, on Flickr

Would have had the sides done left in the morning with it going strong:

https://farm1.staticflickr.com/784/40856151044_b3409b0ebb_c.jpgUntitled by Izzy Mel, on Flickr

But I came home to spaghetti..... UGH!!!!

only completed half of it. 25 hrs down the tubes. Oh well back to the drawing board the next time I will print one side at a time. The part looks great. to bad it didn't finish.

https://farm1.staticflickr.com/873/40856150744_dec6f1158d_c.jpgUntitled by Izzy Mel, on Flickr

WOW! Getting more excited! That interior structure looks so solid! I hope the DXF file successfully transfers when I laser cut the MDF!
 
Hi Gang,

Time for the "End of the Weekend Update"! I hope you enjoy it. :)

I spent all weekend working on the pads! Did some paint testing on the first pad
IMG_20180418_162244_zpsnoerucob.jpg


IMG_20180418_162605_zpsulvlibld.jpg


Trying out different paint colors
IMG_20180418_162926_zpsshkywgbx.jpg


IMG_20180418_162933_zpsqdjtlhep.jpg


I looked all over for the right base color
IMG_20180419_180105_zpsxrbr1e78.jpg


IMG_20180420_055318_zpsw7srcgqc.jpg


Found it!
IMG_20180420_164401_zps7xceml2q.jpg


After painting I sprayed a layer of satin clear to seal all the edges and color
IMG_20180420_185020_zpsdpqa5zd2.jpg


I then mixed a brown and black watercolor wash for that used dirty look we all know and love! ;)
IMG_20180420_185144_zpsg0innjmj.jpg


Covered
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Then simply wiped away... after first coat
IMG_20180420_185651_zpsrkohjhly.jpg


You can already begin to see some details pop out
IMG_20180420_185709_zpsfojwmkkz.jpg


After a few coats of the wash I mixed a highlight color to bring out the raised areas
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Dry brushed
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Added a darker wash to some of the deeper cuts
IMG_20180420_190333_zpsqmqiphov.jpg


Tapped away the excess
IMG_20180420_190342_zpscsbqstfo.jpg


Slowly coming along (the clear coat I sprayed earlier allows me to remove most of the wash if I'm not happy with the results)
IMG_20180420_190401_zpsciloz1dw.jpg


Test Pad is slowly getting there and still needs some extra details
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IMG_20180420_190833_zpsbxxvpmlk.jpg


IMG_20180420_191109_zpshldvva9w.jpg


In place
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It was time to tackle the rest of the pads! I grabbed a few rocks from outside the workshop
IMG_20180421_084720_zpsosandmfv.jpg


Began to add some little details as I went
IMG_20180421_085222_zpsy8evcyt9.jpg


IMG_20180421_085228_zpskyvyttud.jpg


Whew... Lots to do! Each pads takes about 20-30 min cover with the Podge and shop towels
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I love this!
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IMG_20180421_102417_zpstzes9fan.jpg


Wait till you see how this guy turned out! ;)
IMG_20180421_102422_zpsnss19fae.jpg


IMG_20180421_102456_zpso2jelyh0.jpg


After the tops dried I started to cover the bottoms - another 15 min per pad
IMG_20180421_172218_zpsprghqsc5.jpg


A few ready for paint!
IMG_20180422_074851_zpscox1y6cw.jpg


Black undercoat
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More bottoms getting finished up
IMG_20180422_095157_zpsnltflcbp.jpg


That's a LOT of scrap towel
IMG_20180422_095210_zps8btrdxnv.jpg


I also worked on the door pads. I want the textures and colors to match up
IMG_20180422_095605_zpswt26w78a.jpg


IMG_20180422_111738_zpshrebnikq.jpg


More Paint
IMG_20180422_111752_zpsoio677qe.jpg


I remembered... the three top door pads all had to be extended. I added an extra foam strip to the tops then recovered
IMG_20180422_131659_zpsdz1wnjyy.jpg


IMG_20180422_131711_zpsejdamthx.jpg


Finally! The small gap is filled!
IMG_20180422_131746_zps9khbnryo.jpg


His turn!
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Done!
IMG_20180422_120444_zpstfagb12f.jpg


IMG_20180422_142808_zpsgiebqo8w.jpg


Adding the prime color
IMG_20180422_142751_zpsufhmcpyz.jpg


Time to say goodbye and head home!
IMG_20180422_144433_zpsu6tgfc7m.jpg


Alright! Let's add some detail work to these pads!
IMG_20180422_155827_zps042z4mre.jpg


IMG_20180422_155857_zpspdrltntg.jpg


I used the same wash and highlight technique(s)
IMG_20180422_174436_zpsgh1thqzu.jpg


I love how each pad is so different from the other
IMG_20180422_174442_zpsuzxpsmjj.jpg


Adding more dark tones
IMG_20180422_174447_zps1ir4utfd.jpg


More washes and highlights - its a slow process but totally worth it!
IMG_20180422_174457_zpsbxelpfpv.jpg


DEF needs more washes and highlights
IMG_20180422_174509_zpsolxfszwg.jpg


IMG_20180422_174519_zpsu6doecqb.jpg


This pad is weird... I'm not sure if I'm going to cover with more Podge and repaint. What do you guys think? Yes or No to the texture
IMG_20180422_174533_zpsxtw81psn.jpg


IMG_20180422_174547_zpsq0qa9fk8.jpg


OK... let's get serious. Time to break out the paint brushes
IMG_20180422_174931_zpsmo2livy5.jpg


I took a LOT of time to make the grooves look like deep dirt filled cuts. Much better!
IMG_20180422_181734_zpswahmjjql.jpg


IMG_20180422_183726_zpsqw9xl7pv.jpg


I love that deep cut!
IMG_20180422_183748_zpsdgrygoc3.jpg


The work area... Hi, Winky!
IMG_20180422_183956_zpsmmrq630r.jpg


I still have the sides to weather and highlight and then each pad will get a layer of "Satin-Clear" to seal. Many more pads to go!
IMG_20180422_185928_zpsuqcc9i4j.jpg


The center pad is not spotted - the light is reflecting the table center piece onto the pads surface
IMG_20180422_185942_zps572jlree.jpg


And this is where we are... a whole bunch more to go! I'm loving how the pads are turning out!
IMG_20180422_185956_zpswk3x7gls.jpg


More to Follow!
 
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Too...freakin'...cool! You nailed it! Love the detail and the highlighting. Spot on. The door pads look just like the real deal.

A couple of those pics look like it was the 1980's and you just made a run in the Falcon down to Columbia. A little Don Henley playing in the background...

"All she want's to do is dance, dance, dance..."
 
Great update IzzyMel! And yes Sofa, I'm sure these files will be fine for the MDF;)

Hey J,

Iz is really coming through on these 3D prints. He's my new hero. :) I'm looking forward to finally putting the head piece together and mounted in place!

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Too...freakin'...cool! You nailed it! Love the detail and the highlighting. Spot on. The door pads look just like the real deal.

A couple of those pics look like it was the 1980's and you just made a run in the Falcon down to Columbia. A little Don Henley playing in the background...

"All she want's to do is dance, dance, dance..."

Hey K,

LOL! THANKS! I'm really happy with how the pads are turning out. It's a slow process but totally worth the effort and very relaxing.

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Pads are coming out great. I think you nailed it.

Thanks so much, SB! It will be really interesting to see them in place. Now I have to figure out to make the larger pads! Any ideas ;)
 
The "weird pad" looks great...as well as all the others. Love how you worked this out!!!

Hey K,

Thanks!!! The "weird pad" is kinda growing on me. Every now and then, in the real world, there is always that one unit that comes off the line and is rejected by the inspectors. In this case, there are a few pads that slipped past the Inspector 12! ;)
 
Hi Gang,

Just a quick update... The pads are coming along. I'm adding a thick layer of paint to the some of the pads. I didn't add enough Podge to the towels and the spray paint is literally soaking into the towel(s) leaving a less than desirable texture. The great thing about the watercolor paint is that it's cracking in certain areas - the exact the look I was for!

I should have the door pads covered with the watercolor base coat and ready for paint by tomorrow. I still have to route the edges of the "Cockpit Entrance" side pads before adding the Podge and towels but they should be ready to paint by the end of the weekend.
 
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