1:1 Millennium Falcon Cockpit Replica - Group Build

Hi Gang,

Got around the filling, sanding and priming the foot well greeblie. Still lots of work to do!
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I really dislike sanding all the curves and tight areas... I can never get them perfect!
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With acrylic cover plate
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All these pieces have to be joined and then the edges sanded smooth to appear as one solid piece
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I have some ideas for this greeblie that I would like to try to include chrome pin stripes. I want to see if I can replicate the original designers direction from ESB. :)

More to Follow!
 
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Hi Gang,

Early Morning Update! Got the other coil pack mounted!
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I'm really happy with the way these turned out
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EWE... Kinda blurry! Sorry about that!
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Painted the interior side of the Pinball Jet Bumper parts
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And of course more sanding and filling on the foot well greeblie
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I'm very anxious to see how it turns out :)
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Great News! The laser cutter doesn't work again! I think it's safe to say we have NO idea what's going on with it! We're starting from square one and installing Win XP (the s/w it originally worked with when I bought it) to see if that solves all the issues...

UGH!

More to Follow!
 
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SofaKing01 are you going to use the one sided bracket foot well or are you doing the two sided? as always outstanding work.:D

Hey Iz,

Thank you, Sir! DEF going with the single "leg" on the side of the foot well greeblie. The two sided made it look too much like a grasshopper. I have to redesign the leg. It's not as as balanced as would like. When the laser cutter is up and running I'm going to cut a new leg and mount.

- - - Updated - - -

Someone at your shop should really have a button rigged to play the "stalling hyperdrive" sound effect whenever something doesn't work! It's not your fault!

Hey M,

Do you have any idea how sick we would get of that sound byte? It would be non-stop! ;)
 
Hi !

I haven't been here for a long time and I saw the last pictures.
Are you doing a new cockpit 0_o ?

Anyway, that looks amazing, as always !
 
Hi Gang,

Don't you think it's time for an update? ;)

Starting with the new foot well greeblie.... I recut the legs and a few of its details using MDF and 1/8" acrylic
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1/4" details
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I picked up one of those coils lamps a while back and I'm going to mount here and illuminate
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During all this excitement... I forgot to pull the bolt out while the MDF dried... it's stuck
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I then primed the leg
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After punching out the screw I drilled a larger hole for the lamp wiring
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After days of sanding I was finally able to add some paint!
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While the foot well greeblie was off drying I added silver to the Pin Ball parts
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I really liked this configuration
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I think it has that Star Wars look
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Going to mount into this greeblie
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In addition to the Pin Ball parts I cut these
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They will be painted silver and placed here
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I also cut this shape
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This helps me locate the mounting holes
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Put into place
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Drill the holes
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Mounted!
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Added silver
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Adhered into place!
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Many of you might remember Samantha from the Space and Rocket Center... She's now with us full time and stopped by to help add some greeblies to many of the panels! She started off by removing these static light bars and drilling holes for future LEDs
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We laser cut these replacement pieces which will be painted white and have new acrylic "buttons" added
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She then drilled holes into the metal knobs and mounted into place
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Up top and in the corner - Samantha was a HUGE help and we look forward to her continued support! Thanks S! :)
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Now on to the nose! I added these filler strips to the vertical beams. It was easier / cheaper to do this than buy two new pieces of 4x8 sheets
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While adding the strips I didn't realize how this area of the nose was warped. I removed the screw (which helped a lot) and when the nose is separated from the body I'll add a filler piece behind the skin to help push the skin out and match the natural curve of the nose.
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Added strips to the other side
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The main reason for this update is show you how the new Dreaded Volvo panels are coming along! These are not easy... Started with Han's side
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Center support
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Chewie's side - the strips weren't added to the vertical supports yet
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Created a template for the upper panel front on Chewie's side
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Creating the template for the back (note the diagonal line - that is the original width of the window sill/ top of the Volvo panel - which I'll explain further down the post)
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Cut the pieces and...
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I love it when a plan (or lack there of) comes together! ;)
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I then started the upper Volvo panels
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Piece near the front window
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I had to re-cut this piece
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Getting closer! I love how the outer edges follow the exterior curve!
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Switched over to Han's Side
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If you notice, the panel does NOT meet with the edge of the vertical support. The upper Volvo panel is also the start of the canopy window sill. The sill's are approx 2 1/4" wide. Unfortunately, I had to double that width at the back or there would have a massive gap between the Volvo panel and the vertical support. I think adding the additional 2 1/4" was a good compromise. It still retains the original look... Mostly
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Cut the piece with all the associated angles (one side is 16 degrees and the other 21 degrees with a curve - very confusing)
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Cut the front piece to Han's side - which wound up cracking... I didn't cut with the grain... ugh
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Cut the top piece to Chewie's side upper Volvo panel
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Making sure everything fits. Naturally, I had to pick the most warped boards I could find... ugh
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In this pic you can see how thin the panels are at the window. BUT... they finally match the exterior curve! Skinning the exterior side of the panel is going to be fun and challenging! I'm really looking forward to adding the hoses!
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Samantha and I then added bracing to all the corners and T Nuts. The T Nuts will allow me to mount the panels to the vertical supports/body since the Volvo panels will essentially be skinned and sealed. But I'm probably going to add some access panels just in case!
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Whew... and that's that... :) A HUGE thank you to Samantha and Scott for their help over the weekend!

More to Follow!
 
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Hey Sofa,

Phew you guys (and gals) were certainly busy over the weekend, boy are you dedicated.:eek

Are we to assume that the laser cutter is working again or were those parts cut before it died (maybe you should call it Frankenzombie Cutter since it seems to keep dying and coming back to life again, :D)

Roughneckone:cool
 
Hi !

I haven't been here for a long time and I saw the last pictures.
Are you doing a new cockpit 0_o ?

Anyway, that looks amazing, as always !

Hey D,

Great to hear from you. Thanks for the kind words! Believe it or not this is the same "basic" cockpit from many years ago. It's gone through several changes, to say the least, over the years to include lighting, sound and of course the addition of the new nose/window and the exterior skin - coming soon!
 
Hey Sofa,

Phew you guys (and gals) were certainly busy over the weekend, boy are you dedicated.:eek

Are we to assume that the laser cutter is working again or were those parts cut before it died (maybe you should call it Frankenzombie Cutter since it seems to keep dying and coming back to life again, :D)

Roughneckone:cool

Hey R,

Whew... it was a long busy weekend! Had a lot of visitors come through over the weekend as well so work did come to a halt a few times. But it was a good weekend overall. Both Scott and Samantha were a HUGE help!

The laser cutter... :facepalm The software was written for Win XP and seemed to do really well on the old laptop - not a single issue until the actual laptop hard drive failed. We're running Win 7 (I believe) and we're now looking at that as the actual culprit. We're still experiencing intermittent problems. We're going to set up a new PC with Win XP and see if that resolves the issues.
 
Looking good, Sofa. nice to see the outline of that UVP frame coming together. Remember, ice for those headaches

Hey Hey!

Isn't that a nice looking line? I'm so excited to get them skinned! Fingers crossed things go smoothly. My only concern is keeping the frames in their current position/configuration. I know when I remove / unbolt them they will want to return to their natural shape. That's the biggest challenge so far!

Luckily we're getting close to winter so I'll have plenty of ice on hand!
 
Hey D,

Great to hear from you. Thanks for the kind words! Believe it or not this is the same "basic" cockpit from many years ago. It's gone through several changes, to say the least, over the years to include lighting, sound and of course the addition of the new nose/window and the exterior skin - coming soon!

Ok I understand now ! Thank you for the answer ;) ! And you're welcome :) ! Keep doing some great work !
 

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