1:1 Millennium Falcon Cockpit Replica - Group Build

Don't worry sofa if I ever win the lottery you will have the money needed.......

And don't thank me thank you if you didn't do what you do be nothing for me to come look for on a daily basis.

I wish I had more time in rl I'd love to build a r2 unit, a few years back in did make a boba fett set of armour out of papier mashee about as far as my constructive talents have managed (apart from building the lego millennium falcon does that count) go.

Did you still need those hinges I got now you got those other ones?

Loosebruce
 
Don't worry sofa if I ever win the lottery you will have the money needed.......

And don't thank me thank you if you didn't do what you do be nothing for me to come look for on a daily basis.

I wish I had more time in rl I'd love to build a r2 unit, a few years back in did make a boba fett set of armour out of papier mashee about as far as my constructive talents have managed (apart from building the lego millennium falcon does that count) go.

Did you still need those hinges I got now you got those other ones?

Loosebruce

Hey LB,

Fingers crossed! ;)

I appreciate the support and kind words - as always. You guys/gals are the reason I'm doing this - that and I I've always wanted MF for my own! ;)

Time is a luxury many of us don't seem to have. But if you have that desire and really want to build an R2, whether you have 15 min or 2 hours to spend... go for it!

I DEF want to get my hands on those hinges / struts. let me know what I need to do - send me a PM!

- - - Updated - - -

Stinson may be able to help you.

Hey S,

You're timing couldn't have been better! Starkiller and Izzy are now working with each other!
 
Hi Gang,

Time for the "Early Morning Update" Part I

ENJOY!

I started mounting all the greeblies to this panel. I'm hoping to have the extension panel boxes finished up today
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Adding paint to the main panels
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Silver! Time to put it all back together!
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BUT...

Time to jump to the nav chairs! Laser cut these end caps for the pipes
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Adding filler - naturally
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The famous Tupperware lid!
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I have to re-position and resize the hole
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Armrest halves were finally adhered together
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Filler... UGH
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More armrest details - mounting holes will probably change location
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After sanding filler and routing the edges
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"The Hockey Stick" guide. This 1/4" piece of MDF mounts to the bottom of the "Seat" panel. The slits make it easy to find exact placement of the hockey sticks / main frame
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I then started work on the back part of the chair. These curved pieces go on both sides of the frame. These, in my opinion, add to the overall look!
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BUT... I very quickly realized they had to be redone...
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The curved pieces didn't have enough meat to mount lay/adhere the skin. Do I fill the entire piece with individual cuts?
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Adding / laser cutting more details and templates
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Back side with the curved panels
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Slowly coming together
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Time to add some primer to the first chair
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And armrests!
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I then routed the edges of the main chair panels
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HMMM a office chair?
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New hole guide!
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PERFECT!
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Getting there!
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Daniel and I spent another long Sunday with the CNC... This time our adventure included cutting aluminum!
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More nav chair parts!
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We then jumped back to the ply... redesigned back panel curved pieces
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Armrest and other pieces
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That's a lot of sanding, filling, sanding, etc
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The previous back curved panel was MDF but that wasn't enough meat to adhere any type of skin. So I redesigned and bulked it up
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I headed back to the workshop, broke out the belt sander and had a few pieces to sand smooth
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Just a few
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And a few more
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3rd set of armrests!
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Armrest support pieces
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Take one these...
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Adhere 7 of them together
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Stake them all up side by side and wait for them to dry - YES, all the holes aligned!
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I'll then cut these to shape as well
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And this is where we are... a big pile of scrap! ;)
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Hang tight! Part II Coming!

Another HUGE THANK YOU to Daniel for putting time in on the CNC!

More to Follow!
 
Wwoooaaah carving up the metals!!! Top level modeling. Before attaching the arm rests, have you thought about making them flip-up-able so it's easy to get in and out? It's just a case of fixing both sides to a bar at the back, etc-etc....
 
Loving watching your progress, We've had a bit of downtime will be back on ours soon, your chairs are looking fab!
 
Hi Gang,

UPDATE: PART II

I have spent the last two days sanding and filling the nav chairs... It's been brutal! In between drying I was able to knock out a few other nav chair and extension panel related tasks. I hope you enjoy Part II! :)

Chewie's Extension Panel is finished! I wound up having to move a few things in order to bolt the panel in place but I like how it turned out!
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I mod'd this side piece to allow for the wire connector
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Its amazing how horrible paint looks when its wet
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Painted the bolt holes silver
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When I went to bolt the panel in place I found this gap... this was where the original canopy mounted
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No problem! Just cut a filler piece
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Adhere the interior panel skins
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Need to get these wires connected!
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I'm really happy with the way this panel turned out!
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The new bolt holes look like they were there all along!
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Slowly working on this guy...
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On to the NAV CHAIRS!

This is my collection of used sanding blocks from the last 2 days!
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3 nav chairs to make in 2 days?
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Most of these images show the sanding and filling... I didn't want to bore you guys too much
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Armrest mounts - more on these later!
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Finding center
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As you can see I removed the headrest portion of these panels. After Stormy posted those AMAZING images of his Nav Chair this forced me to go back and redesign a LOT of little things - and I'm ok with that!
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Just as I was about to finish this cut a bug flew into my eye... Nothing scarier than a flying piece of ply wood! UGH
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Headrests
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Filler...
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Nav Chair #2
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More filler
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Nice...
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Can you see it? Filler...
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And more filler...
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Primer!
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2nd round of filler...
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Remember... I have to wait for ALL this filler to dry!
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2nd round of primer
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Primer
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Whew... finally finished!
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PAINT!
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Before I go ANY further with the chairs... I was going to use aluminum to cut these nav chair pieces but decided to hold off - glad I did after seeing Stormy's chair! But it was FUN practice and filled the time in between waiting for primer/filler dry!
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More Fun!
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Primer
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Black
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Silver
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So... you take all these pieces...
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And these...
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Put them all together
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Again... this
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Plus this
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Equals this
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You then add this
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And you get this!
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All 3 - again these are just practice to see how they look
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On to the new Headrest
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The Lid
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Back side... notice the slots
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These metal pieces we cut are the brackets used to mount to the frame - more later
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I then adhered the side pieces
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I'm not sure whether to cut the headrest from aluminum. Daniel was nice enough to give me an old sheet he had. BUT... I just priced a 2'x4' sheet of 1/8" aluminum... 95 BUCKS! That's a bit much!
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I then added super glue to the edges as a test. I want to see how hard the edges get
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Back to the nav chairs...

I cut this simple hole guide
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Used the guide to drill holes into the base
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HMMMMMM ;)
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3 chairs
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I mounted a second pedastal and...
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Not sure if these pedastals will be strong enough. We might fab an actual rectangular base
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But wait... this guy sits all alone
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And now... This is the very first time the "near finished" nav chairs have EVER been in the cockpit!
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And this is where we are!
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WHEW... I'm sorry/frustrated I didn't get as far as I would have liked. The wait time for the primer and filler was a killer! The hardest part is behind us... let the FUN begin! :)

Stay Tuned! More to Follow!
 
Last edited:
Wwoooaaah carving up the metals!!! Top level modeling. Before attaching the arm rests, have you thought about making them flip-up-able so it's easy to get in and out? It's just a case of fixing both sides to a bar at the back, etc-etc....

Hey W,

Thanks! It's a slow process watching the CNC work its magic but its so worth it!

I've thought about making the armrest flip up but I'm not sure how to execute without sacrificing screen accuracy. Plus, it's tough to figure out when you dont have much surface space to play with.

Also, were there armrests on the original Martin Baker ejection seats?

- - - Updated - - -

Waiting patiently for "Part II"... :) tick-tock tick-tock tick-tock...

Hey T,

Hope I didn't disappoint! ;)

- - - Updated - - -

Loving watching your progress, We've had a bit of downtime will be back on ours soon, your chairs are looking fab!

Hey S,

Thanks so much! I appreciate your taking part! Any time away from a project is both positive and frustrating. Hopefully yours was for the better. :)
 
It seems to be a lit of wood in the navchairs, but I guess it will be necessary. People will probably be plopping down in them.

Hey FF,

I would have rather gone with the aluminum but a single 1/8" 2x4ft sheet is 95 dollars! For that price I would only be able to CNC the back panel. For the same amount I can cut 3 near complete chairs out of 3/4" Birch Ply. Plus, wood is very forgivable. If I mess up... just add filler and primer.
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I'm not sure whether people will be sitting down until I can ensure a good solid pedestal. Always a work in progress.

EDIT: Corrected a few errors :)
 
Last edited:
Keep an eye on Craig's List. I could have had 5 or 6 3x5, 1/8" sheets several weeks ago for $100, but had no use for them at the time.

Hey FF,

I would have rather gone with aluminum but a 1/8" 2x4ft sheet is 95 dollars! The back panel of the chair alone would run that much. For the same amount I can cut 3 near complete chairs out of 3/4" Birch Ply. Plus, wood forgivable. If I mess up... filler and primer. :)

I'm not whether people will be sitting down until I can ensure a good solid pedestal. Always a work in progress.
 
Great progress! So interesting to follow. I come here every monday to check the update. Just a question, maybe I missed something: why three nav chairs? I'm no millenium falcon expert like you guys, but I thought there were only two in the cockpit. Are you building it ahead in case you make the whole ship interior?
 
Hi Gang,

A quick early morning "random" update! I've been working on small random details to help make the nav chair more accurate... I wish I knew the actual names of the areas I'm working but it will all make sense as it comes together. Enjoy!

I cleaned and prepped all the metal pieces
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Painted with etching primer - before sanding
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After
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This large piece is mounted to back side of the chair and appears to sit / mount to the "ejection tube"
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I adhered these oddly shaped pieces together
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Where the metal piece will mount
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I then laser cut these brackets for the back part of the chair
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Headrest and back panel pieces
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The brackets wrap around these pieces which will be adhered to the top of the back panel
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Headrest pieces
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The two headrest pieces are on the backside of the headrest panel where they attach to the "brake pad" looking greeblie
20170322_181148_zpsyfpqtj7a.jpg


Metal "brake pad" added
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It looks something like this
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Side bracket will mount the headrest to the hockey stick frame -but at a tilt toward the seat
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More headrest frame details
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I really like how these are turning out but they have to be redesigned
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I then broke out the long drill bits!
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Enlarged the holes in the armrest supports
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Where a threaded rod will fit
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The threaded rod will also go through the main hockey stick frame mounting the 3 pieces together for strength and durability - I hope!
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Finally I designed and laser this mounting template for many of the metal greeblies and other details on the sides of the hockey stick frames
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The template rests on the side of the frame where I can now easily locate all the mounting points for all the metal greeblies
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I wont mount anything until I have more of the larger side greeblies - so the template might change.

Stay Tuned! More to Follow!
 
Great progress! So interesting to follow. I come here every monday to check the update. Just a question, maybe I missed something: why three nav chairs? I'm no millenium falcon expert like you guys, but I thought there were only two in the cockpit. Are you building it ahead in case you make the whole ship interior?

Hey OC,

Thanks! I appreciate the continued support!

The reason I'm building 3 chairs is that I plan on making the nav computer as well. It will be a nice change of pace from the cockpit but also mark off another MR related prop. :)
 
This project is unreal. Man sofa you are incredible. This is something that you will always have to be proud of, amazing work....simply amazing. Can't wait to see it completed.

Sent from my 2PYB2 using Tapatalk
 
This project is unreal. Man sofa you are incredible. This is something that you will always have to be proud of, amazing work....simply amazing. Can't wait to see it completed.

Sent from my 2PYB2 using Tapatalk

Hey B,

Thank you so much for the very kind words. It's been an amazing journey so far! We're so close to finishing (before starting all over again)! We're all really excited as well! :)
 

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