1:1 Millennium Falcon Cockpit Replica - Group Build

Snow Builder said:

Love watching you put the cockpit together. With all the beautiful work (paint, pinstripe, greeblies) it really looks like they should "do" something.

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Hey SB,

Thanks! It was really nice getting those panels together. A HUGE thanks Huntsville Scott for all his help over the weekend! It's funny you mention functionality... the plan is to have ALL the switches do one thing are another (sound, LEDs, etc).

SteveStarkiller said:

such a thing of beauty. Hey is there any update on chairs? I remember seeing something about the reupholstering, and the skeleton of the nav chairs. this is something I've been itching to see go into your build! I'm sure you're on it, just curious.

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Hey Hey!

Thank you, my friend! Couldn't have done most of this without ya! Looking forward to when you can finally see it in person.

The Nav Chairs - I am currently reworking all the digital files and hope to get started soon. Most of the chair details can be cut on the laser cutter with simple PVC pipes and other misc items to complete the look but the main rails need to be CNCd using furniture grade wood - ply isn't going to hold up. I can always cut by hand, but we're going to need at least 3 sets. Much easier, faster and more accurate done with a CNC. I'm still not sure what I'm going to use for the padding. Maybe a thick foam with leather-like upholstery? We're still talking about that one... OH! The main overhead cowl has already been designed and broken into 4 pieces for 3D printing (HUGE THANKS to Izzy for taking the time to create that iconic part of the chair).

The captains chairs (2 sets of them) are slowly being attended to as well. We have the smaller Huntmaster seats that will accompany the stand alone center console and then the JEG racing seats that will be foamed up and fitted as close to screen accurate as we can get. As you know, this is it! Celebration is next April so EVERYTHING has to be finished. The cockpit HAS to look as if it was literally "plucked" off the MF.



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joberg said:

What can I say Sofa? Always good to see the progresses made on that cockpit. That front window looks the bomb!

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Thank you, my friend! Forward progress is GOOD progress. Starkiller and OperaScot did an amazing job on that front window! It was so fun putting it together and even better seeing her in place. It changes the look of the entire cockpit.

Loving your stuff, I've watched this build for so long, it's looking fantastic!!

Not sure if this has already been posted but PropShop unveiled their 1:1 scale replace of a millennium falcon panel @ SDCC - can't imagine that's cheap ;-)

http://www.theverge.com/2016/7/26/1...rce-awakens-collectibles-props-comic-con-2016

Hi Gang,

Does anybody know of a good filler I can use that is both sand-able and "FLEXIBLE"? The window sees an incredible amount of stress when it's removed and shuffled about and the cracks are becoming bigger and more noticeable.

Ideas?

DaftAider76 said:

Loving your stuff, I've watched this build for so long, it's looking fantastic!!

Not sure if this has already been posted but PropShop unveiled their 1:1 scale replace of a millennium falcon panel @ SDCC - can't imagine that's cheap ;-)

http://www.theverge.com/2016/7/26/1...rce-awakens-collectibles-props-comic-con-2016

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Hi DA76,

Thanks so much! I appreciate your staying power!

I've seen ProShop's cockpit replica. Considering they were the team who built the EPVII movie set... I would expect nothing more than 100% accuracy to the TFA version It really is a thing of beauty.

Looks great. My favorite part is when you put all the elements together. My least favorite part is sanding updates. Kidding.

SofaKing01 said:

Hi Gang,

Does anybody know of a good filler I can use that is both sand-able and "FLEXIBLE"? The window sees an incredible amount of stress when it's removed and shuffled about and the cracks are becoming bigger and more noticeable.

Ideas?

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When I need to fill with strength, I use epoxy. If it needs to be somewhat flexible, which generally isn't true of epoxy, I use Gorilla Glue Epoxy labeled as "Impact-Tough". It is *somewhat flexible*, but strong and gap filling like regular epoxy.

I can't recall if I've sanded it before, but I'm pretty sure I have.

Just be sure you give it 24 hours to cure.

Rebelscum said:

When I need to fill with strength, I use epoxy. If it needs to be somewhat flexible, which generally isn't true of epoxy, I use Gorilla Glue Epoxy labeled as "Impact-Tough". It is *somewhat flexible*, but strong and gap filling like regular epoxy.

I can't recall if I've sanded it before, but I'm pretty sure I have.

Just be sure you give it 24 hours to cure.

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Thanks, P! I'll give that at a try in some of the lesser seen areas and see if it works. Those cracks are really getting annoying.

How about mixing some epoxy in with the filler possibly give best of both worlds.

Loosebruce

Loosebruce704 said:

How about mixing some epoxy in with the filler possibly give best of both worlds.

Loosebruce

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Hey LB,

That's an idea. I have LOTS of scrap laying around. I hope to find a good solution.

Ah I'm so happy now you're putting her back together... i have goosebumps. Well done!!! Cheers Éric.

Looks horrible and inaccurate. You're going to need to start all over again and scrap it all...

Daboudzi said:

Ah I'm so happy now you're putting her back together... i have goosebumps. Well done!!! Cheers Éric.

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Hi E,

Thanks so much! I get happy when she's back together as well. I suddenly remember why we're doing all of this in the first place!

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BobaFalcon said:

Looks horrible and inaccurate. You're going to need to start all over again and scrap it all...

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You're right... I failed.

Cor, them alignment shots! What a handsome craft!! Such lovely lines!!!

Hi Gang,

This is one of those "Not So Exciting" updates...

Painted the radio cassette greeblie... I'm probably going to recut/design this greeblie




I love the shape of it




Lots More to Follow!

Sofa,

Constantly amazed at the attention to detail! That panel looks absolutely stunning and here you are talking about a redesign. This project COULD have been done years ago, I am sure, in some rudimentary form but you are striving for a stunning recreation and that is something to be proud of.

Starwoid

Starwoid said:

Sofa,

Constantly amazed at the attention to detail! That panel looks absolutely stunning and here you are talking about a redesign. This project COULD have been done years ago, I am sure, in some rudimentary form but you are striving for a stunning recreation and that is something to be proud of.

Starwoid

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Hi S,

Thanks so much! And you are correct. The cockpit could have been finished long ago had it NOT been for our desire to have it perfect and screen accurate! We're taking a tremendous amount of pride and care into this project. It has been and continues to be both a curse and a blessing. Every time a new photo drops of the cockpit and/or we discover/identify a greeblie, it "forces" me to go back and redo / redesign. Again... curse and a blessing.

Our motto is "Good Enough is NOT an Option". Sadly, there are so many errors that I'm tempted to fix but there comes a point where I have to stand back and tell myself these changes and different build approaches will be applied to the new cockpit.

SofaKing01 said:

Hi Gang,

Does anybody know of a good filler I can use that is both sand-able and "FLEXIBLE"? The window sees an incredible amount of stress when it's removed and shuffled about and the cracks are becoming bigger and more noticeable.

Ideas?

Click to expand...

Have you tried shoe goo products? I'm sure you can sand it after it has cured (used to repair skate shoes with it and the grip/sand paper top would eventually wear it down and smooth it out) so, there's a possibility??

Hi Gang,

I think it's about time for an update!

There was a LOT going this weekend to include an incredible amount of attention focused on the laser cutter. After all we've been through we think the new controller is bad and has to go back. We just can't get the laser to 100%. It's been VERY frustrating... (UPDATE - it turns out the Config file is in fact the wrong file for our controller. The vendor is emailing new s/w and a config file :facepalm)

One of the many things we did was remove the laser tube and create a new adjustable bracket. OH NO... the laser juice spilled out!


Now we can adjust up and down and left and right. We also spent several hours focusing the laser... that was fun!


I did manage to cut a few things. I created this bolt pattern part of the gas regulator - note how BAD the edges are


Test fit


Perfect






Sanded






A mixture of filler and wood adhesive








Filler - first of many coats I'm sure






Primer Filler! Yeah!








More filler










During all of this chaos I jumped from task to task... One of them being getting these new Volvo Panels started


Slight overhang on this side to match up with the upcoming metal frame for the skin




I then marked out the path of the panel only to find out that on the other end...


Look at the top of the panel... this is how much I have to work with... UGH! But we'll make it happen!




I believe this is a VERY good example why there has never been an actual full scale interior/exterior screen accurate cockpit built / displayed


BUT... before I could move forward on the Volvo Panels I had to address the mounting points for the canopy beams on the front window










Still lots to do...


I then mounted the nose cone skin






I need to remove material from the underside curve so the front and rear edges align with the edges of the nose cone and don't interfere with the window


Note how the front edge is overlapping the window. If this were a stationary display it would have been perfect!




The heat and humidity were WAY up so I halted work on the Volvo Panels (between noon and 4 it's brutal outside) plus I need to think exactly how the panels are going to mount to each other. I did manage to laser cut a few more objects but the Config File proved to be loaded with errors and all these pieces were scaled wrong! Another UGH


Too Big




Too Big - BUT all is not lost...Fellow RPFer Fuzz will be getting more greeblies VERY soon.




Too Big






Nav Computer Greeblie... Oh yeah... WAY Too Big!








We built a shelf to hold all the large material


During transport some of the wiring tends to get caught or snagged on various things so this morning (Sun) I cut covers that will simply be Velcro'd into place


It gives it such a clean look


Daniel was up until 3am (Sun) working on that blasted Config File. He managed to fix several things but the laser cutter is still giving us real problems... another UGH... BUT the scaling issue has been resolved and I was able to recut a few things. New screen accurate eye bolts / greeblies


I had to slightly redesign in order to fit the existing holes where the previous "eye bolts" mounted


Adhering them together


Tips


Test fitting






Filler added to the edges. I'll sand them smooth this evening and hope to get some color on them as well




New Nav Computer Greeblie
















And there she sits...


So much more coming, gang! When the weather breaks and starts to get cool... I'm going Full Throttle! A huge thanks to Scott, Daniel and Philip for their help over the weekend! Thanks, Guys!

As I mentioned, it turns out the Config file is in fact the wrong file for our controller. The vendor is emailing a new Config File and updated s/w to accompany the controller. Finger Crossed this solves the issues!

Stay Tuned For More!

Forgive me, bit of a daft question - and I may have missed it in the thread - but is there a reason as to why you call the Volvo panels, well, volvo panels?
Forever impressed by your and your teams work, Sofa!