1:1 Millennium Falcon Cockpit Replica - Group Build

I was thinking of building a section of the death star 1:1 scale (Hangar bay 327 control room as well as a corridor with some turbolifts), what materials could i use to build curved walls, would flexi-play be substantial enough?, by the way just discovered this thread and the stuff you do is absolutely incredible :)

Hi L,

Thanks so much and welcome to The RPF! :)

My first thought... GO FOR IT! Dont think... do it! Second, I would try using 1/8" MDF. At that thickness, MDF is very durable, flexible and, depending on where you find it, can be very inexpensive. I get my sheets of MDF for $8 ea. Most lumber warehouses should sell MDF (in various thickness) in 4 foot by 8 foot sheets.

Hope that helps!
 
$8 for a 4 X 8 sheet of MDF:eek What's the thickness on that baby???????????? And, if true, I'll move to Alabama next month:D!
 
$8 for a 4 X 8 sheet of MDF:eek What's the thickness on that baby???????????? And, if true, I'll move to Alabama next month:D!

Hey J,

That's the cost for the 1/8" MDF. I haven't priced out 1/4" but I would assume around $15 for a single sheet - which is still very cheap!. Check around and see if any of your local lumber warehouses stock MDF :)

- - - Updated - - -

It has been a long time (almost 2 years) since I checked on this thread, but I absolutely LOVE what I'm seeing! Great job guys!

Hey PR2!

Great to have you back! Thanks so much for the kind words! Lots of dedicated and talented folks helping on this project. And there is NO end in sight! :)
 
Hey PR2!

Great to have you back! Thanks so much for the kind words! Lots of dedicated and talented folks helping on this project. And there is NO end in sight! :)

Glad to be able to watch this continues! I remember talking to you back then about possibly moving that way, but the job offered better pay and I ended up staying. Still visit Alabama every so often, and really want to stop by and see it all in person and maybe cut a few board with y'all.. expecting a baby in March so hopefully if I can't make it down by then, there might be a "PropReplicator3" present as well ;) best of luck!
 
Glad to be able to watch this continues! I remember talking to you back then about possibly moving that way, but the job offered better pay and I ended up staying. Still visit Alabama every so often, and really want to stop by and see it all in person and maybe cut a few board with y'all.. expecting a baby in March so hopefully if I can't make it down by then, there might be a "PropReplicator3" present as well ;) best of luck!

Hey PR,

Congrats on all of life's little changes! Hopefully you and the mom to be are doing well? :)

I have good news and bad news... The bad news is that the cockpit is no longer in Alabama. It's with prop company getting a layer of skin and the canopy finished up. That's the bad news? Kinda... the good news is that the prop company is located in Dallas, TX!

I'll let that sink in for a moment... ;)
 
Hey PR,

Congrats on all of life's little changes! Hopefully you and the mom to be are doing well? :)

I have good news and bad news... The bad news is that the cockpit is no longer in Alabama. It's with prop company getting a layer of skin and the canopy finished up. That's the bad news? Kinda... the good news is that the prop company is located in Dallas, TX!

I'll let that sink in for a moment... ;)

Hmm.. so your saying that I have to drive 3 hours instead of 14?? Sounds like a deal ;)

Pm incoming :)
 
Hi Gang,

The "End of the Weekend" update is coming! I've been trying to figure out these Inkjet Water Slide Decals and didn't want to post anything until I could call it a success! Had a few alignment issues but the process itself is/was VERY simple.

Pics coming in a few hours! :)
 
Hi Gang,

No update this evening. Photobucket is going through site maintenance. Better to just wait until their finished...

Stay Tuned! :)
 
Hi Gang,

Time for the "End of the Weekend Update"! Sorry for the delay... Let's get to it!

First and MOST important... Fellow RPFer, Wavey, identified, found and delivered THIS real world greeblie - the auto pilot clutch! For those of you who don't know, this greeblie is mounted on the back wall just behind Chewie's Nav Chair! THANKS, WAVEY!!!!
IMG_20180816_172542_zps5kcutwpu.jpg


IMG_20180816_172547_zpseyk0yle0.jpg


IMG_20180816_172608_zps7r3cvl21.jpg


This is one of my FAVORITE greeblies!
IMG_20180816_172638_zpsnzcuf7nk.jpg


IMG_20180816_172646_zpskruqkwjw.jpg


Sanding, filling and priming the captain's chair continues
IMG_20180818_085606_zps410brsmx.jpg


This might be coat 10 or 12
IMG_20180819_093738_zpsrcbdr8ng.jpg


These 3D printed Nav Chair TRMs (Thank you, Iz) had to be re-primed with a special primer. The resin in the 3D prints had not fully cured and paint was NOT taking... UGH
IMG_20180818_085617_zpsaciwja9e.jpg


Lost some of the finer details but it had to be sealed - I'll lightly sand after the primer dries
IMG_20180818_085626_zpshmw1g3gs.jpg


Shapeways does some pretty amazing stuff!
IMG_20180818_085634_zps8jdbdzlr.jpg


I was able to laser cut these tiny 1/32" plexi TRM plates just before the laser cutter finally gave out - I ordered a new 10,000 hour tube. Should be here soon
IMG_20180818_091108_zpsqsbjv55x.jpg


Pencil for scale (didn't have a qtr)
IMG_20180818_091120_zpsc78jq2ho.jpg


After a very light sanding of the primer / sealer I adhered the plates
IMG_20180818_110608_zpsixvwsrsl.jpg


IMG_20180818_110615_zpspwprdyek.jpg


Multiple thin and quick passes with the flat black
IMG_20180819_095203_zps2u1wy7sk.jpg


IMG_20180819_095212_zpsetc1jjzj.jpg


I primed these full scale center console greeblies
IMG_20180819_095117_zpsyk7gsg20.jpg


Can't wait to get them finished up and mounted back into place!
IMG_20180819_095122_zpscjamhdsc.jpg


IMG_20180819_095128_zpsfafgkjjl.jpg


I'm going to paint the same way as the originals but I'm DEF going to add a bit of fun...
IMG_20180819_095136_zpsf7rl7bo4.jpg


Black
IMG_20180819_123035_zpsh4g06nmg.jpg


IMG_20180819_123045_zps2ymscbws.jpg


I then painted the 1/4 scale console black - the humidity was WAY up and drying time took forever
IMG_20180818_083315_zpssixh2krp.jpg


IMG_20180818_091242_zps9lqx4vkd.jpg


IMG_20180818_092208_zpsas3e5cr0.jpg


IMG_20180818_092217_zpsy0ol0c02.jpg


After what I "thought" was enough drying time, I found a few flaws in the console so I sanded the questionable areas and then covered with primer... Did I mention the humidity was WAY UP!?
IMG_20180818_121430_zpsf7qoi87s.jpg


UGH
IMG_20180818_121435_zpsh40k5xsu.jpg


IMG_20180818_121441_zps7qy3ha54.jpg


Every single surface cracked...
IMG_20180818_121701_zpsbg297t51.jpg


IMG_20180818_121710_zpstsvfuu0v.jpg


While I let the disaster primer dry I spent a few minutes on the instrument panels
IMG_20180818_110556_zpsdlsnmg3j.jpg


I had to find a way to keep these back panels in place
IMG_20180818_110716_zpsjvurr33e.jpg


Picked up this magnetic strip
IMG_20180818_120910_zpstfvway6j.jpg


Cut a small practice piece
IMG_20180818_120942_zpsxxburvuh.jpg


Adhered the sister magnet to the cover
IMG_20180818_121039_zps009lbazh.jpg


PERFECT! The magnets are thin enough for both layers to fit just underneath the panel cover
IMG_20180818_121051_zpsbf2zweok.jpg


IMG_20180818_121314_zpsug8xskzi.jpg


Before the laser cutter finally quit on me, I did manage to cut these guide pieces
IMG_20180818_130546_zpslt3pclao.jpg


The idea is these sit inside the instrument panel snug around the interior edges
IMG_20180818_130552_zpsd6rkayp6.jpg


But they are adhered to the back cover plate giving me a perfect guide for them to nest and not move around when in place
IMG_20180818_130723_zps2w1na8j7.jpg


IMG_20180818_131639_zpstn9fkpy5.jpg


They fit right into place
IMG_20180818_131653_zpspq2qvsbu.jpg


Adding some primer
IMG_20180819_093812_zpsmxhhdisq.jpg


IMG_20180819_093817_zps8cgcjszx.jpg


The primer dried and I sanded the console smooth - that was a LOT of fun!
IMG_20180818_123223_zps9vovqlkl.jpg


IMG_20180818_123230_zps11txfhge.jpg


IMG_20180818_123235_zpsmk8k11pz.jpg


Cover plates work perfectly! Still need to work the upper instrument panel
IMG_20180818_123246_zpsjnhopyvz.jpg


IMG_20180818_123321_zpsqmwvekty.jpg


IMG_20180818_123329_zpsltafdoth.jpg


I then repainted everything flat black and brought back to the house
IMG_20180819_171119_zpshiz1vgay.jpg


IMG_20180819_171134_zpsqo4atg3a.jpg


I bought some aluminum HVAC tape and applied to the back side of the main body panels - this will help illuminate the panels and spread the LED light around
IMG_20180819_101250_zpsq892jkzf.jpg


Aluminum on one side and super sticky tape on the other
IMG_20180819_101257_zpsipb7l4lm.jpg


Its a long process - the tape wants to stick to itself
IMG_20180819_101733_zps0qirqvay.jpg


Press the tape into place, smooth any bumps and locate any and all holes to punch
IMG_20180819_101739_zpsbr3bom9m.jpg


IMG_20180819_101921_zpsx053kapd.jpg


Front side - nothing sticking through
IMG_20180819_101934_zpse2jyirpu.jpg


Carry on...
IMG_20180819_103038_zpsmnbayxmq.jpg


Top panel done
IMG_20180819_105052_zpsfjyrlvb3.jpg


Shiny
IMG_20180819_120048_zps13dpfg1c.jpg


Han's side done - I'll finish Chewie's side this weekend
IMG_20180819_120042_zpspgw3wbax.jpg


Now for the FUN PART! I finally figured out, with some relative success, how to print and create my own inkjet water slide decals! Practice print
IMG_20180818_175542_zpscyzalubw.jpg


Second print - slightly darker...
IMG_20180818_175618_zpsxsju8xrf.jpg


HMMM... Somewhere in between is the correct color
IMG_20180818_175639_zpsfynzf0ke.jpg


Before finding the matching color let's see if these decals actually work. I included some of the switches to the practice print
IMG_20180819_062443_zps6xhwcro2.jpg


Set the decal in water
IMG_20180819_062707_zps3p6rhhmt.jpg


SUCCESS!!! I printed the first few test pieces on clear paper
IMG_20180819_062743_zps9wbg9qev.jpg


Let's try the white paper - SUCCESS!!!
IMG_20180819_063236_zpsstqkequd.jpg


The process is fairly simple. You can buy both white and clear background decal paper. Print your image using a Inkjet printer and then simply spray 3-5 coats of satin, gloss or flat clear onto the image and wait 24 hours to dry, cut out the decal and place in water for 2-4 min or until the paper backing slides away from the decal. Like I said... VERY simple.
smile.png


Here we go!!! Our first actual print on 11x17 white decal paper
IMG_20180819_084832_zpsj5dybjvs.jpg


After sealing the inkjet print with 3 coats of satin clear
IMG_20180819_170936_zpsrkv7blb9.jpg


I cut the decals
IMG_20180819_151502_zpsz2dftnbb.jpg


The first 3 panels and console armrest waiting for some color
IMG_20180819_171001_zpstzuglczd.jpg


I have to admit I had a few misprints and misaligned decals (deleted 15+ photos of the disaster). The pin stripes were just TOO close to the edges. What I quickly realized is that sanding all the panels and adding filler, etc removes/alters just enough of the original edges to make the decal edges slightly too large or too small.

BUT... The 3rd time was the charm! I scaled / realigned the outer pinstripe edges, reprinted, sealed, cut the decals to shape and placed in water for 2-3 min
IMG_20180820_164033_zps5cosik77.jpg


This is where I'm a little disappointed... The black ink is NOT as deep as I would like it to be and I'm not sure how to calibrate the printer to print what's on screen
IMG_20180820_164201_zpsx4zxzrjj.jpg


Armrest decals in place - these look really good. The two competing colors help make the black more vibrant
IMG_20180820_165845_zpsoinchron.jpg


Sadly, the armrest had to be reprinted
IMG_20180820_165856_zps2vfesgkw.jpg


This decal was printed 4 times! I wasted a LOT of paper. As you can see the black is not as deep as it should be against the regular black paint
IMG_20180820_165911_zpsbxuyv76h.jpg


It still looks really good and the holes align perfectly!
IMG_20180820_165916_zpsxixxcdmk.jpg


Once everything is in place I will go over all the panels with a final coat of satin clear to seal the decals to the panels
IMG_20180820_170314_zpstcu4qjld.jpg


The lower instrument panel decal is NOT in place yet - a new decal is getting its final coat of satin clear
IMG_20180820_170337_zps60utauqb.jpg


I have to recut a new MDF/acrylic nose panel for the decal to fit
IMG_20180820_170722_zpsik3mfbdl.jpg


Back panel - you can see the holes punched for the tiles
IMG_20180821_153340_zpsgi4gzx8q.jpg


This process was LOTS of fun. I had to carefully cut small "Xs" into the openings for the tiles to fit
IMG_20180821_153349_zps8znkwadd.jpg


NICE!
IMG_20180821_153924_zpstbdawc5d.jpg


UGH... Slight error
IMG_20180821_153933_zpsu8kdq5zu.jpg


IMG_20180821_153942_zpscfchprrv.jpg


I then temp placed all the tiles into position - you can see where the paper was stressed
IMG_20180821_155348_zpsxm5k6se3.jpg


It does look cool! :)
IMG_20180821_155409_zpsjomvcpzg.jpg


And this is where we are!
IMG_20180819_123126_zpsz7o8qstq.jpg


The next few weekends are my prepping for the upcoming Galactic Swag Con in Dallas, TX on Sept 8! Lots to do!!!! Hope to see some of you there! :)

Stay Tuned!
 
Last edited:
"Pencil for scale (didn't have a qtr)"

Ha! I read this as pencil for sale...and "didn't have a qtr" as more evidence you must be hard up for funds!!!
 
"Pencil for scale (didn't have a qtr)"

Ha! I read this as pencil for sale...and "didn't have a qtr" as more evidence you must be hard up for funds!!!

LOL! After dumping all that money into a laser cutter tube I need all the help I can get! ;)

- - - Updated - - -

Fantastic job Sofa...love the idea of the decals and they look very good btw!!

Thanks, J! I'm really happy with the decals in general. I just wish I could make the black ink less purple - which is what black essentially is. But it's coming along!
 
Sofa, thanks for the update!

The decals look good. I seem to remember people used to buy special printers (Alps) just to get high-quality decals. I don't know if you have the best inkjet for them or not. I'm sure ther are people here who are much more insightful on that. But as an idea, what about leaving the black areas of the decal clear so they show the underlying paint? Also, I'm sure just like shapeways, there are places that can print them for you, so long as you are very sure on the final dimensions. Also, have you considered dry-transfers for the graphics too?
 
Ditto the above. I haven't made any myself (which makes me a self declared expert) but I have heard the same about the ALPS printer. However, just use clear decal paper and let the black paint be your background. Cut the decals as close to their edge as you dare then spray the completed panel with whatever type of clear finish you're looking for.

Also, cut your holes before you wet the decal. MUCH easier to control your cuts. You might even want to sharpen some HF hole punches to get (relatively) round cuts.

Of course, you could always hand stripe the panels (hee hee). Remember how much fun that was in 1:1 scale ?!?
 
So impressive about the found greebly. What’s the back story?

The captain chairs look amazing!

The NAV chairs and parts are semi-gloss black [emoji6]
 
Hi Gang,

Let's get the "End of the Weekend Update"

Unfortunately, summer is still here! After a beautiful week last week, summer came back with a vengeance with high temps and unbearable humidity so I had to cut the weekend short. Also, it was nothing but frustration from the new printer! The colors dont match, print heads are not aligning, etc etc etc... BUT...

The new tube for the laser cutter arrived. Unfortunately, we now need a NEW power supply to handle the power. UGH
IMG_20180823_155311_zpsrxla5pc2.jpg


I printed new decals of the 1/4 scale console
IMG_20180823_164444_zps0ifbttmm.jpg


The new decals fit perfectly!
IMG_20180823_165433_zpsen6fywwq.jpg


Armrest decal
IMG_20180823_165438_zpsbmxfo3cv.jpg


IMG_20180823_180258_zpsn8zt3uox.jpg


IMG_20180823_180306_zpslv16pfyo.jpg


I just can't seem to get a good print
IMG_20180823_180328_zpssm8lajfv.jpg


Back panel
IMG_20180823_180345_zpsoonx5hnb.jpg


IMG_20180823_180437_zpsi9ig9ywh.jpg


QTR for scale
IMG_20180823_180450_zpsnz6vpam5.jpg


Blue and white tiles
IMG_20180823_180512_zpsdx0evtrh.jpg


I hope all this effort will be worth it in the end...
IMG_20180823_195146_zpsiij5sl6q.jpg


IMG_20180823_195158_zpskdjvkt8r.jpg


I read on a few modeling sites that vinegar and water help relax decals. So I added the mix to the holes
IMG_20180824_151429_zpsxcdzcjxt.jpg


IMG_20180824_151441_zpsn2kntp53.jpg


Which in the end proved utterly useless
IMG_20180824_151448_zpswxgcyry6.jpg


I then worked on the full scale armrest levers
IMG_20180823_191050_zpsskqdxxcp.jpg


Masked them off
IMG_20180825_075125_zpsjhtxu0vx.jpg


Sanded and added some greeblies
IMG_20180825_080125_zpsniclvws8.jpg


IMG_20180825_080130_zpslrzh7m5y.jpg


Painted silver
IMG_20180825_081651_zpskvo5d8ke.jpg


IMG_20180825_081656_zpsjumrwssf.jpg


IMG_20180825_082249_zpsolrjk25u.jpg


IMG_20180825_082306_zpszasfxves.jpg


IMG_20180825_082315_zps3ltdghwz.jpg


I wanted to add some visual interest to the sides of the levers so I designed this
IMG_20180825_133715_zpsos07jld8.jpg


Printed on Clear Decal Paper, the idea was to give the illusion of a shift guide
IMG_20180825_133734_zpsws1gkmhw.jpg


And that didn't work out too well...
IMG_20180825_134108_zpsepiumdaf.jpg


I then tried on white paper...
IMG_20180826_074424_zpsiwbpicj7.jpg


That was even worse...
IMG_20180826_075054_zpsknr3go4j.jpg


So I went back and stuck with the basics
IMG_20180826_091854_zpsfaavw4oa.jpg


IMG_20180826_091903_zpsa0tefajl.jpg


IMG_20180826_092340_zpsipryuvif.jpg


I like the simplicity of it and the red compliments the silver
IMG_20180826_092348_zps3pq2pbhk.jpg


I then scaled down a bit and worked on the 1/4 scale versions
wink.png

IMG_20180825_090352_zpspjnb6wqe.jpg


Kudos to Izzy for these awesome 3D models
IMG_20180825_090359_zpstgi3pqzg.jpg


First layers of paint
IMG_20180825_091058_zpsn8otpphy.jpg


IMG_20180825_095217_zpsufebj0y4.jpg


For scale
IMG_20180825_095227_zpszcsahqcf.jpg


IMG_20180825_095237_zps2je3zuqp.jpg


Adding more color
IMG_20180825_105238_zpsqfgcl4k4.jpg


IMG_20180825_110856_zpszewjadph.jpg


IMG_20180825_111343_zpstkyurrah.jpg


IMG_20180825_111403_zpsdeau1chz.jpg


IMG_20180825_124705_zps9ukwqg48.jpg


IMG_20180825_124956_zpspf2yweb4.jpg


IMG_20180825_125004_zpsze0v3y11.jpg


I had two more pads to get finished up and then sent to Dallas!
IMG_20180825_134931_zpsral8vvvx.jpg


I like the look, but the pads are a but too rough so I added more Podge
IMG_20180826_090254_zpsp2duuxex.jpg


The 1/8" LED strip arrived
IMG_20180825_130357_zpsbopogdgx.jpg


The fit perfectly inside the clear acrylic tube - this part is going to be interesting!
IMG_20180825_131307_zps4gnopzx0.jpg


Finally... I added the aluminum tape to Chewie's side
IMG_20180825_125338_zpscvggskpv.jpg


And that's where we are! A frustrating weekend...

More to Follow!
 

Your message may be considered spam for the following reasons:

If you wish to reply despite these issues, check the box below before replying.
Be aware that malicious compliance may result in more severe penalties.
Back
Top