Building The ANH 5'Millennium Falcon

eagle1 · Aug 11, 2017

Vacformedhero said:
Agreed , the Japanese Star Wars Chronicles Vehicles episode 4,5,6 , I have it too, larger format images , less text (thankfully as all Japanese , but google translate works well on the phone) it's expensive but since I've committed to building the falcon it's a great investment.
View attachment 749319 View attachment 749320
Stu, brilliant to see an update on the builds, I just got modern Koolshade for mine , I'll still hunt for the vintage but for the moment I'll cross that off the list )

The modern koolshade is I think 17 louvres per inch as opposed to 21 for the vintage yes?. Do you see much of a difference?. I have the vintage shade, stuffs like gold these days to find. I did see a guy in Spain I think it was, selling a big vintage sheet on Facebook, think that got snapped up quick!.

- - - Updated - - -

greeble_gremlin said:
Wow !
Lookin' good Stu, you're really making head-way.

Cheers Mike, c'mon man you gotta start your build, join the fun...or is it madness haha.

greeble_gremlin · Aug 12, 2017

Hey Stu,

Man you don't know how badly I want too start my bird!
I've had all the kits stockpiled for a while now, (with the exception; finally added the 1/25 Centurion)
I'm finally ready to post about the 1/12 X-Wing (look for the thread soon ) also some 1/18 scale X-wing and new 1/24 Laser cut wings kit.
As soon as that project out the door, I can turn my attention to the Falcon.

I should have a big pressure pot by then... a must for good castings, which is a must for building the Falcon.

Stu I am curious about your solution for the "curved" "hamburger bun" part of the hull.
What did you come up with?

greeble_gremlin · Aug 12, 2017

The 5'-Footer project is so big... I can't get my head around it all at once. I need to do like you, and just focus on one section at a time.
I would like to start with the gun turrets, - that would get me "stoked" on this build.

Your Quad Laser cannons look great by the way!

I also have not contributed to the Falcon builders community as much as i would like too.
I hope I can give the Falcon builders an acceptable solution to the Kool-Shade issue.

I did make these last February. The test prints worked out great ! ...more durable than I had hoped.
As these have a pass-thru grill they are not cast able but will need to be 3D printed. ..still cheaper than real Kool-Shade.

Normally the Virtual Kool shade is too "delicate" as an actual "grill" ( the 3D printed material does not have the tensile strength of real metal/brass)
..But because of the ring/frame there is added strength. I was also able to add support from the back side of the grill, which remains hidden quite nicely
These grills are of course too "perfect". -- I need to go in and bend up the louvers, which won't take too long, got to make 6 unique rings though (each is bent-up a bit different)

I will also make some VKS for the sections along the top of the docking bay ridges.
Those will have "backing" so they will be castable and much cheaper to reproduce than 3D Printing each one.
I also did some experimenting with the section of Kool Shade on the Cockpit Tunnel.
I think I can provide a convincing "castable" version of the VKS for this section which will also bring down the cost.
There is the issue of the diameter of the Cockpit Tunnel, some folks are building their's at different diameters.

I'm not sure if there would be much interest for an affordable Kool-Shade substitute.
The modern stuff might look just fine on the Falcon (without the 21 louvers per inch next too it, to compare too)

eagle1 · Aug 17, 2017

greeble_gremlin said:
The 5'-Footer project is so big... I can't get my head around it all at once. I need to do like you, and just focus on one section at a time.
I would like to start with the gun turrets, - that would get me "stoked" on this build.

Your Quad Laser cannons look great by the way!

I also have not contributed to the Falcon builders community as much as i would like too.
I hope I can give the Falcon builders an acceptable solution to the Kool-Shade issue.

I did make these last February. The test prints worked out great ! ...more durable than I had hoped.
As these have a pass-thru grill they are not cast able but will need to be 3D printed. ..still cheaper than real Kool-Shade.
View attachment 751238 View attachment 751239 View attachment 751240
Normally the Virtual Kool shade is too "delicate" as an actual "grill" ( the 3D printed material does not have the tensile strength of real metal/brass)
..But because of the ring/frame there is added strength. I was also able to add support from the back side of the grill, which remains hidden quite nicely
These grills are of course too "perfect". -- I need to go in and bend up the louvers, which won't take too long, got to make 6 unique rings though (each is bent-up a bit different)

I will also make some VKS for the sections along the top of the docking bay ridges.
Those will have "backing" so they will be castable and much cheaper to reproduce than 3D Printing each one.
I also did some experimenting with the section of Kool Shade on the Cockpit Tunnel.
I think I can provide a convincing "castable" version of the VKS for this section which will also bring down the cost.
There is the issue of the diameter of the Cockpit Tunnel, some folks are building their's at different diameters.

View attachment 751241 View attachment 751242 View attachment 751243

I'm not sure if there would be much interest for an affordable Kool-Shade substitute.
The modern stuff might look just fine on the Falcon (without the 21 louvers per inch next too it, to compare too)

Heya Mike,

Well hurry up, you know you want one bad haha.
X-Wing parts looking great, boy that project has gone on for quite a few years now huh, my abandoned effort back when is long forgotten...gulp!.

I will post on the hull build later on when I have something to show & can post up progress pics describi g the process. I have it worked out, just getting my mandibles done for now.

I think your workings on the koolshade will be invaluable to other builders to have the opportunity to have the real deal alternative. This stuff is fast disappearing, if any left at all now...who knows. The newer shade is nice but the louvre count is noticeable.

Stu

eagle1 · Oct 1, 2017

More progress. Starboard side mandible nearing completion. A few donors yet to place in the pit wells & chipping & adding pipework to do. But starting on the port side mandible in the meantime.
This thing is wonky, the actual miniature I mean. To replicate all those intricacies is all part of the building process, but it slows you down somewhat to achieve a good replica.
I will have acrylic beams that slide through the mandibles from the core that will provide alignment & strength. Not sure yet if I will have the mandibles as removable or glue them in place.

Stu

bigpetr · Oct 1, 2017

Beautiful. Keep pictures coming please

)

Moska · Oct 1, 2017

thumbsup :love

thumbsup

joberg · Oct 1, 2017

Huge beast for sure and lookin' Ace!!

TazMan2000 · Oct 1, 2017

Size does matter. Great build. Glad you're still on it.

TazMan2000

eagle1 · Oct 10, 2017

Cheers guys, yes for sure pics will keep on coming. I'll post up some progress of the port mandible in construction as well as the pits over the weekend.

Stu

eagle1 · Feb 25, 2018

Some more progress. The large underside pits worked on. The McLaren pit has a only a few parts to add & the Tiger ll/Chieftain pit a number of parts to add & a few more pipes.
Mandibles still require the relief chipping & still a few more parts to add in various pits. Kits acquired as I go along, which seems a never ending cycle haha.
Masters for the sidewalls & jawbox plates are nearing completion & casts will be done, as per ILM.

satazius · Feb 25, 2018

Wow. Amazing to see this come together. Thanks so much for sharing these in-progress pics!

t2sides · Feb 25, 2018

EXCELLENT Work Stu!!! Pro work all the way!!! Your attention to detail, and clean lines and applications are just amazing! You are absolutely nailing the details and putting this together so nicely! Keep up the great work, and the excellent progress pics!!! So cool to see another 5 Footer coming on line!!
Sean

seven · Mar 3, 2018

eagle1 said:
The mandible pits are interesting in themselves. No two seem to be alike in diameter to make the donor parts fit correctly. So each one has to be carefully placed out, sometimes two or three times to get things sitting right.

Is the depth of the mandible pits all different too?

eagle1 · Mar 3, 2018

Yes. When building the pits I had to keep two things in mind...depth & width. Certain kit parts gave the depth indicator as to a particular pits depth. Of course this determines the pit that sits immediately underneath as well, but when you have one depth sorted the other kind of falls into place & can be doubled checked to make sure there is enough clearance for both in the internal mandible space. It's tight in there for sure & the odd kit part was trimmed, say a landing gear, to fit the pit sidewall. I built my pits separately & fixed in place later, keeping in mind the correct orientation. ILM would have detailed the pits out in situ, but seemed easier for me to do separately & work out diameters & depths.

Stu

eagle1 · Sep 3, 2018

Thought I'd post some progress on my hull dome work.
I realised early on & couldn't find a place in New Zealand anyway to blow mold one piece domes, that really, there is no point to full domes, why wouldn't a half dome or even a quarter dome section work!. So that's what I have done, built an oversize quarter section form or tool, to have the domes vacformed in 4.75mm ABS. The tool is oversized to allow good pulls & trimming when placed on my core. The tool was all CNC'd MDF. Just finishing up the skinning now, which is 3mm MDF. All this will be sanded smooth & filled if needed & sanded again & sealed. Then it will be down to the plastic formers for vacforming. 10 pulls will be needed for 1 Falcon, 8 for the 2 domes,1 for the engine deck & the last for the engine petal strips & maybe another as a spare.

kokkari · Sep 3, 2018

That is simply incredible!

Sent from my SM-G955U using Tapatalk

eagle1 · Sep 4, 2018

kokkari said:
That is simply incredible!

Sent from my SM-G955U using Tapatalk

Thank you sir!. The tool is pretty heavy as you can imagine, but at least it won't move on the vacform bed haha.

Flixen · Sep 4, 2018

Fantastic idea!
Thanks for sharing.

ModelBuilder · Sep 4, 2018

Awesome job with this Stu!

Building The ANH 5'Millennium Falcon

Sr Member

Sr Member

Sr Member

Sr Member

Sr Member

Attachments

Active Member

Sr Member

Legendary Member

Master Member

Sr Member

Sr Member

Attachments

Well-Known Member

Master Member

Sr Member

Sr Member

Sr Member

Sr Member

Sr Member

Well-Known Member

New Member

Similar threads