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  1. Member Since
    Aug 2015
    Messages
    76
    Apr 17, 2017, 12:47 PM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8851

    Hi SK

    Looking good and major progress you've got going on. Have you thought about wrapping those cracking parts in a thin sheet of Alu, the type that a printing plate might be made of? Given I've noted you'd said you were a designer, you should be able to get your hands on some used printing plates???

    R
  2. Roughneckone's Avatar
    Member Since
    Nov 2003
    From
    The Void
    Messages
    542
    Apr 17, 2017, 4:27 PM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8852

    Hey Sofa,

    On the cracking, you could maybe try giving the arms a complete skim coat of bondo. If you only sand it smooth and not quite down to the wood segments it should stay smooth and the cracks shouldn't reappear!

    Roughneckone
  3. SofaKing01's Avatar
    Member Since
    Apr 2010
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    Huntsville, AL
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    Apr 18, 2017, 5:01 AM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8853

    joberg said: View Post
    Beauty parts there Izzy Mel...as for those Nav chairs Sofa; wow! Lots of work for those alright (details,details, details!!) Cracks in the arms will be there to stay I'm afraid...I don't have any tricks (apart from making them in one solid piece of plastic or metal) that will help you over time.
    Hey J,

    Iz is doing an amazing job! I can't wait to see these pieces printed!

    The cracks are frustrating but there is another detail that goes on those armrests and I think that might solve the problem with the cracking. We'll find out when we get there!

    - - - Updated - - -

    rubble said: View Post
    Hi SK

    Looking good and major progress you've got going on. Have you thought about wrapping those cracking parts in a thin sheet of Alu, the type that a printing plate might be made of? Given I've noted you'd said you were a designer, you should be able to get your hands on some used printing plates???

    R
    Hey R,

    Thanks so much! I'm not sure about the alum. As I mentioned above there is added detail that I forgot about. I should be able to get the strength I need when those two pieces are added - per arm.

    - - - Updated - - -

    Roughneckone said: View Post
    Hey Sofa,

    On the cracking, you could maybe try giving the arms a complete skim coat of bondo. If you only sand it smooth and not quite down to the wood segments it should stay smooth and the cracks shouldn't reappear!

    Roughneckone
    Hey R,

    I thought about a Bondo as well when I mentioned the fiberglass resin. I'm DEF going to use the Bondo when I add those two detail pieces. Fingers crossed that it works!
  4. Member Since
    Aug 2015
    Messages
    76
    Apr 18, 2017, 6:26 AM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8854

    Hi SK

    Had'd realised there were additional part. Could you not put a tension bar through it like the back piece? Counter sink the front and then fill it over?
  5. SofaKing01's Avatar
    Member Since
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    Huntsville, AL
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    Apr 18, 2017, 9:23 PM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8855

    rubble said: View Post
    Hi SK

    Had'd realised there were additional part. Could you not put a tension bar through it like the back piece? Counter sink the front and then fill it over?
    Hey R,

    There are 2 1" half round rubber strips that run across the back of the part in question. If I put a mounting plate behind them it should keep the piece from flexing especially with the larger "Numbered" plate I just added.

    I'll see how the plate works before adding anything else. I was hoping the threaded rod would take care of the tension but I found out very quickly that over tightening one side just a bit causes all the cracking.
  6. SofaKing01's Avatar
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    Huntsville, AL
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    Apr 24, 2017, 7:37 PM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8856

    Hi Gang,

    Dont you think its time for an update?

    What a great week its been! I mean that with all sincerity! Lots of time with the CNC, a few set backs here and there, a few changes as well and then capped it off with a a visit from some great folks!

    Finally painted one of the access panel doors




    And installed




    Still need to install the cabinet door struts - which are now primed


    Got this guy all finished up


    Laser cut these new pipe surrounds






    Mounting brackets to help the pipe surrounds stay mounted to the frame






    Look something like this


    I laser cut this hole guide


    Marked and drilled


    Drilled these metal pieces and created a countersink




    Just need to prime and paint


    More pieces designed and laser cut


    PRIMER!


    These pieces fit on the inside and align the top piece and pipe




    LOVE IT!


    Mounted


    EH... screws look too big




    More Primer




    Filler


    After a few hours of sanding and filler... more sanding and filler




    Changed the screws and painted black




    More primer


    Painted black


    I laser cut this spacer piece


    Counter sunk this area


    Dry fit - now all the bolts and hinge areas dont hit the frame


    Lousy pics!






    I then designed this piece - based on several images I've received from J and S!


    Dry fit




    Paint!




    Nice and solid!


    Getting this guy ready to be molded!


    Need to counter sink those screws a little more


    Daniel and I spent a fair amount of time with the CNC over the weekend. We cut these new back support panel with the padding insert routed out!


    Edges routed




    Primer


    Filler


    Sanded and more primer


    The screw I used a bit too big for the hole... UGH




    All fixed


    More touch-ups




    I then spent a LOT of time with the nacelles. They gave me SO MUCH GRIEF!




    More spot filler


    This one is at a 90% solution


    This one... Not so much!


    Day 2 with the CNC! I decided to break away from the single thin post pedestal that was used in the OT so I designed a new box frame








    And then 120 of these little guys!


    So where did this weekend take us?

    Now... the chair has a more solid footing




    This top piece looks awesome!


    Other side of the headrest mounted


    Coming together!




    Nacelle Temp in place. I think they're going to turn out!


    Kinda sticks out but I think I can fix


    These pics are just horrible!


    I know the new seat pedestal looks odd but trust me! It's much more solid and is actually MUCH safer! This also avoids having to create and weld a plate and post.


    BUT THAT'S NOT ALL!!!!

    Last Thursday, fellow RPFer Fuzz's folks stopped by and spent the day in Huntsville before making their long drive back home to Texas after geeking out at Star Wars Celebration! They were not only kind enough to take a few things to Fuzz for me but they also brought along a few of their projects!

    Minion


    L3-FTY (made from "leftover" parts)


    Can't remember this guys name!




    These little guys are 2/3rd Scale R2 units - NOT full scale


    Its a tight fit! And yes... they were zooming all around the workshop! It was so much fun!


    The whole gang!




    Is this the first time R2 has been in the cockpit?


    We had a great time! Two of the nicest people I've ever met and they are welcome back anytime! OK... Fuzz can come too!


    And this is where we are!


    A HUGE thank you to Daniel for taking time out to help CNC and to Fuzz and his folks, D & C, for making the project much more fun! Hope you guys had fun!

    Stay Tuned! Lots more to follow!
    Last edited by SofaKing01; Apr 26, 2017 at 6:07 AM.
  7. Junkyard Jedi's Avatar
    Member Since
    May 2012
    From
    Lubbock, Tx
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    13
    Apr 24, 2017, 8:52 PM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8857

    Thank you Sofa for the opportunity to visit your amazing project, you and your team have done an out of this world job. As I said, any Star Wars fan would love to see this up close and personal. We will all be blessed when you get this out in the public eye, for all to see.

    I posted a few pictures on Facebook on the R2 Builders page, and the fans went wild, Now at 121 likes, loves and comments of WOW!!! Amazing!!!.

    Fuzzual and I will be back to help in any way we can
    Thanks
    Dan
  8. joberg's Avatar
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    Sep 2013
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    Apr 25, 2017, 11:15 AM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8858

    AAAAAAAAAAAAAAMAZING!!!!!!!!!!!!!!!!!!!!! Where to begin? Nav Chairs: love it, getting there for sure (great new sturdy base it seems). The shot of the lit cockpit: priceless!!
    And the R2 unit are way cool!
  9. RPF Premium Member Fuzzual's Avatar
    Member Since
    Jun 2010
    From
    Colorado
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    1,636
    Apr 25, 2017, 11:45 AM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8859

    Thank you so much my friend. I am so jealous that my folks and my droid got to see this in person. We really appreciate the amazing hospitality!!! Still the best build around!

    B
  10. Wavey's Avatar
    Member Since
    Dec 2011
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    529
    Apr 25, 2017, 6:30 PM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8860

    Great update!!! And with the lights on too!!!
  11. Friendly flyer's Avatar
    Member Since
    Mar 2016
    From
    Oslo, Norway
    Messages
    382
    Apr 26, 2017, 4:18 AM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8861

    Wow, just wow!
  12. SofaKing01's Avatar
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    Apr 2010
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    Huntsville, AL
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    7,131
    Apr 26, 2017, 5:25 AM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8862

    Junkyard Jedi said: View Post
    Thank you Sofa for the opportunity to visit your amazing project, you and your team have done an out of this world job. As I said, any Star Wars fan would love to see this up close and personal. We will all be blessed when you get this out in the public eye, for all to see.

    I posted a few pictures on Facebook on the R2 Builders page, and the fans went wild, Now at 121 likes, loves and comments of WOW!!! Amazing!!!.

    Fuzzual and I will be back to help in any way we can
    Thanks
    Dan
    Hi D,

    Thank you so much! It was my pleasure. And thank you for the continued support and kind words. You and C were/are so much fun and I really look forward to the next visit. Also, thank you for helping with the project. Those extra set of eyes solved a lot of problems and helped make everything move forward.

    Look forward to the next visit!
  13. SofaKing01's Avatar
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    Apr 2010
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    Huntsville, AL
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    Apr 26, 2017, 5:34 AM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8863

    joberg said: View Post
    AAAAAAAAAAAAAAMAZING!!!!!!!!!!!!!!!!!!!!! Where to begin? Nav Chairs: love it, getting there for sure (great new sturdy base it seems). The shot of the lit cockpit: priceless!!
    And the R2 unit are way cool!
    Hi J,

    Thanks! It's been so nice seeing all those panel lit up again! We found a few loose connections and changes that need to be done but seeing her lit after all this time is always fun.

    I'm loving how the chairs how turning out. Still have 2 more to go and the new bases/pedestals will make a HUGE difference. I have a few things to add to the base, cross beams to bolt the actual chair in place and a MDF skin with a few simple greeblies here and there (that's going to be fun).

    - - - Updated - - -

    Fuzzual said: View Post
    Thank you so much my friend. I am so jealous that my folks and my droid got to see this in person. We really appreciate the amazing hospitality!!! Still the best build around!

    B
    Hey B,

    Again, it was my pleasure. We had an absolute blast! Have your mom tell you about lunch.

    I'm looking forward to the whole clan coming to visit. That's going to be an insane geek out!

    - - - Updated - - -

    Wavey said: View Post
    Great update!!! And with the lights on too!!!
    Hey W,

    Thank you so much! I thought Christmas should come a little early this year.

    - - - Updated - - -

    Friendly flyer said: View Post
    Wow, just wow!
    Thanks FF!

    I'll take that all day long!
  14. SofaKing01's Avatar
    Member Since
    Apr 2010
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    Huntsville, AL
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    Apr 26, 2017, 5:44 AM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8864

    Hi Gang,

    Just a quick morning update!

    Got a package in the mail the other day... Izzy was kind enough to send me a few goodies! One full scale handle and some 1/4 scale pieces for the 1/4 scale cockpit I'm working on - I haven't seen that in a while!


    There are two handles mounted to the canopy frame. Can't install these parts until then...


    The first of many coats of primer


    I made a slight error so I recut a hole template


    These greeblies were slightly off center


    Sanded and filled the old holes


    Waiting for the paint to dry


    Top one mounted... and then I found a few more errors so I had to wait for the filler to dry


    A few close up pics of the new pedestals


    I still have a few things to add - cross beams and a MDF skin


    The CNC made this so easy!


    A HUGE THANKS to Izzy for printing those parts!

    Stay tuned for more, gang! Lots going on in the background...
  15. Friendly flyer's Avatar
    Member Since
    Mar 2016
    From
    Oslo, Norway
    Messages
    382
    Apr 26, 2017, 6:19 AM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8865

    SofaKing01 said: View Post
    Hi Gang,

    Just a quick morning update!

    Got a package in the mail the other day... Izzy was kind enough to send me a few goodies! One full scale handle and some 1/4 scale pieces for the 1/4 scale cockpit I'm working on - I haven't seen that in a while!
    http://i778.photobucket.com/albums/y...psluqgvvmf.jpg
    I've been hanging around here too long, I actually recognise where a few of these bits go!
  16. SofaKing01's Avatar
    Member Since
    Apr 2010
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    Huntsville, AL
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    7,131
    Apr 26, 2017, 4:06 PM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8866

    Friendly flyer said: View Post
    I've been hanging around here too long, I actually recognise where a few of these bits go!
    LOL! Consider yourself hired!
  17. IzzyMel's Avatar
    Member Since
    Nov 2009
    From
    Severn MD
    Messages
    360
    Apr 26, 2017, 5:15 PM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8867

    Thank you Sofaking01 for the kind words. . I'm happy to be able to help out in any way I can. Let me know how the handle works out. Also looking forward to seeing some of the 1/4 scale stuff as well.
  18. SofaKing01's Avatar
    Member Since
    Apr 2010
    From
    Huntsville, AL
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    7,131
    Apr 27, 2017, 5:26 AM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8868

    Hey Iz,You never stop impressing!Im looking forward to when you knock everyone back, including me, with what you're working on now!
  19. trainman's Avatar
    Member Since
    Dec 2012
    Messages
    265
    Apr 27, 2017, 7:04 PM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8869

    Re: R2-D2 in the cockpit... I would love love LOVE to see R2 and 3PO attempt to fly the Falcon (in a movie sequel) under unusual circumstances, though something tells me it will be a missed / lost opportunity. I think BB-8 rules the roost now. Oh, well...
  20. SofaKing01's Avatar
    Member Since
    Apr 2010
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    Huntsville, AL
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    7,131
    Apr 29, 2017, 10:18 AM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8870

    Hi Gang,

    A quick little teaser update!





    More to Follow!
  21. Friendly flyer's Avatar
    Member Since
    Mar 2016
    From
    Oslo, Norway
    Messages
    382
    Apr 29, 2017, 11:13 AM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8871

    Is that lower pick a weathered bit of the nav chair? If so, that's amazing weathering!
  22. SofaKing01's Avatar
    Member Since
    Apr 2010
    From
    Huntsville, AL
    Messages
    7,131
    Apr 30, 2017, 7:12 PM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8872

    Hi Gang,

    Another quick teaser! Enjoy





    Stay Tuned!
  23. SofaKing01's Avatar
    Member Since
    Apr 2010
    From
    Huntsville, AL
    Messages
    7,131
    May 1, 2017, 7:06 AM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8873

    Hi Gang,

    Weekend Update Part I. Enjoy!

    Continued work on the new back supports


    Two rounds of filler, sanding and primer later


    The pipe greeblies got some attention!


    New pipe caps




    Adding super glue




    Primer, filler and 1st round of sanding later... more filler!


    3 stages of work!


    Another quick round of filler needed




    My hands were SO sore!


    Lots of laser cutting, redesigning and making things fit




    Time to work on this frame greeblie combo


    I was originally going to use screws but I really wanted it to look like the original so I dug through my collection of bolts




    This required me to change the hole size on many of the greeblies - so I had to recut many of the pieces




    Sanding and primer


    Dry fitting


    Interior side... UGH... UGLY MESS!


    Sanded, filled and painted


    This piece is going to be molded


    Primer!


    More details


    Primer




    Paint!




    The bolts and screws will either weathered or painted black




    Another dry fit


    Interior side nice and clean... BUT


    Decided to use 1/4" MDF for the interior side plate


    Adhered this guy into place






    MUCH BETTER! The 1/4" MDF adds a lot of bulk








    And then I had my "UH OH" moment... Will a nut fit?


    YES! Perfect fit!


    Added filler to the AWESOME grab handle greeblie Iz printed for me! This will also me molded


    I then weathering these cool looking greeblies














    AHHH... finger print! I got rid of it!


    I was short a few of these interested greeblies so I fired up the laser cutter








    I both love and hate primer/ While it covers many mistakes it also points so some glaring errors and much needed fixes!


    Heavy sigh




    Started on the other 4 seat nacelles








    Which leads to this...






    I got SO excited I added primer a bit too soon


    Forgot to add this detail


    As you can see, the nacelle in the back fought me the entire way! The edges kept popping free


    PRIMER!


    TEST FIT!








    When mounted, those vertical greeblies mount on the frame act as a "guide" for the nacelles






    In several photos, the nacelles have red covers on them. So, before install the necessary font, I created these (not sure if I'm going to use them)


    UGH!!!!


    More super glue


    Finally got started on seat #2!


    Drilled a few holes


    I used a mortise bit and made sure I had another piece of wood clamped to the other side to minimize too much splintering when the bit breaks though


    How did it turn out? Not to good! lol




    First layer of paint - I'll go back and sand smooth before adding another layer


    I put together the seat pedestal and rested in place




    It was now time to figure out how exactly to mount the chair to the new pedestal - I cut two pieces that will frame in the sides of the chair


    Measured out and cut two holes


    Using a bolt and "T" Nut


    I drilled two larger holes on each side. This allows me to feed to the bolt and washer through and then thread to the "T" Nut that is mounted on the interior side of the pedestal - more pics later


    UGH... this is why drilling pilot holes is SO necessary!


    Let's get some paint on these nacelles!






    I painted the back side of the back support panel black


    When everything dried...




















    And this is where we are... for now!


    Stay tuned! Part II Coming up!
  24. joberg's Avatar
    Member Since
    Sep 2013
    Messages
    4,611
    May 1, 2017, 7:54 AM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8874

    Love the shot with all those googly eyes on the nacelles Made my day Sofa! These Nav Chairs are the bomb! Eager see them completely finished.
  25. Daboudzi's Avatar
    Member Since
    Dec 2015
    From
    Montréal, Canada
    Messages
    25
    May 1, 2017, 1:03 PM - Re: 1:1 Millennium Falcon Cockpit Replica - Group Build #8875

    Oh SofaKing Those nacelles are "Eye" poping!! LOL Wonderful work!! Okay now I need to build something!!
    Cheers Éric.

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