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  1. joberg's Avatar
    Member Since
    Sep 2013
    Messages
    5,206
    Oct 14, 2017, 10:05 AM - Re: 5 Foot Falcon Replica - ANH #26

    Man, that's beautiful
  2. RPF Premium Member Stormy320's Avatar
    Member Since
    Dec 2001
    From
    Pasadena, CA
    Messages
    2,003
    Oct 14, 2017, 1:48 PM - Re: 5 Foot Falcon Replica - ANH #27

    Most impressive
  3. RPF Janitor RPF Premium Member Lear60man's Avatar
    Member Since
    Jan 2003
    Messages
    4,155
    Oct 14, 2017, 3:08 PM - Re: 5 Foot Falcon Replica - ANH #28

    I love this build.....please keep the updates coming.
  4. t2sides's Avatar
    Member Since
    Apr 2005
    From
    Denver, Colorado
    Messages
    310
    Oct 16, 2017, 8:31 PM - Re: 5 Foot Falcon Replica - ANH #29

    Thanks!! Appreciate the comments!
    Got the domes bonded to the 'patty' now. I made the rough cutouts for the 'pits' and the antenna dish, then flipped it over and cut out the two larger 'pit' openings for the underside. I'll leave it upside down from this point and build up the entire bottom first, apply the dome edges, then the side details, then flip it back over and finish up the top.
    Finished up the Docking Arm Port for the top also (except filler putty needed in front of the Sherman), so both top docking arms are near ready to go. Once bonded to the domes, then I'll do the plating/greeblies to the sides of them.
    I also cleaned up the two lower docking arms. They'll get plating/top parts added next, then bonded to the lower dome. So here's a few progress shots:

    Hard to see, but the top access pits all cut out.
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    Placing one of the built up pits just to see it in there. These will all be placed up on stands to fit properly in the pit openings.
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    The Top Port Docking arm mostly done

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    Both Top Docking arms with parts on
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    Dry fitting the lower docking arms. (looking at the front)

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  5. Member Since
    Dec 2005
    Messages
    46
    Oct 17, 2017, 1:33 PM - Re: 5 Foot Falcon Replica - ANH #30

    It's so fascinating to watch your build progress! Spectacular!!
  6. JediMichael's Avatar
    Member Since
    Nov 2013
    From
    I live on earth.
    Messages
    1,994
    Oct 17, 2017, 6:11 PM - Re: 5 Foot Falcon Replica - ANH #31

    Quite a job building something like this. Really nice looking.
  7. marvin's Avatar
    Member Since
    Aug 2007
    From
    Delft, The Netherlands
    Messages
    359
    Oct 18, 2017, 3:26 AM - Re: 5 Foot Falcon Replica - ANH #32

    Lovely build. Nice and clean.
  8. RPF Premium Member eagle1's Avatar
    Member Since
    Mar 2007
    From
    New Zealand
    Messages
    921
    Oct 18, 2017, 5:45 AM - Re: 5 Foot Falcon Replica - ANH #33

    So cool to see the domes bonded Sean, such a milestone to get the hull sealed up!. I'm not too far away from doing the same, albeit a slightly different method.
    Again...you work so darn fast my friend, but your work is always flawless & clean!.
    Going to be amazing seeing all the pits in place.

    Stu
  9. joberg's Avatar
    Member Since
    Sep 2013
    Messages
    5,206
    Oct 18, 2017, 7:18 PM - Re: 5 Foot Falcon Replica - ANH #34

    Beautiful work; Pro-Job all the way
  10. t2sides's Avatar
    Member Since
    Apr 2005
    From
    Denver, Colorado
    Messages
    310
    Oct 21, 2017, 9:34 PM - Re: 5 Foot Falcon Replica - ANH #35

    Thanks again Fellas!!! Yeah Stu, your build and progress is equally impressive!!
    Here's a few updates, finished the port walkway, and started mocking up the lower engine deck. After thats done, it and the walkways will get bonded down, then the recess pits going in. (PS - on the pic with the mandible, that is the SB mandible right side up, even though the hull is upside down - just there for a quick test fit)

    Engine Deck started

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    Engine Deck walls mocked up
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    Both underside walkway tops done
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  11. Member Since
    Sep 2010
    Messages
    392
    Oct 21, 2017, 9:58 PM - Re: 5 Foot Falcon Replica - ANH #36

    You guys will have to explain me how you can be accurate to cut a part yo fit a curved surface,,,,, Perpendicular to it or not....
  12. Treadwell's Avatar
    Member Since
    Aug 1999
    Messages
    10,872
    Oct 22, 2017, 4:46 PM - Re: 5 Foot Falcon Replica - ANH #37

    maxhebus said: View Post
    You guys will have to explain me how you can be accurate to cut a part yo fit a curved surface,,,,, Perpendicular to it or not....
    You lay a sheet of sandpaper on that surface and rub the part until it fits.
  13. Member Since
    Sep 2010
    Messages
    392
    Oct 22, 2017, 5:14 PM - Re: 5 Foot Falcon Replica - ANH #38

    I meant for long panel build like:


    The sides are perfectly cut round to fit the main body clear part. I'm pretty sure that was not rubed on sand paper applied on the Plexiglas.
    Same thing for the cockpit corridor tube connecting to the curved shaped body....
    Treadwell said: View Post
    You lay a sheet of sandpaper on that surface and rub the part until it fits.
  14. joberg's Avatar
    Member Since
    Sep 2013
    Messages
    5,206
    Oct 22, 2017, 6:59 PM - Re: 5 Foot Falcon Replica - ANH #39

    Marvelous job
  15. t2sides's Avatar
    Member Since
    Apr 2005
    From
    Denver, Colorado
    Messages
    310
    Oct 22, 2017, 7:19 PM - Re: 5 Foot Falcon Replica - ANH #40

    Treadwell is right maxhebus! The rough contour is figured out, laser cut out of acrylic (for the walkways at least), then I use a combination of a belt sander and dremel to get the contour closer, then fine tune with varying grits of sandpaper. It's very much raw fabricating in order to get a flush fit. Particularly with making the bevel, all hand ground and sanded. Same goes with the cockpit tube, but with that fella, I cut a paper template, draw an outline on the tube, rough cut with a dremel, then fine tune again with dremel drum and then sandpaper. This is truly 'old school' hand labor, but the results are quite nice.

    Joberg and other folks, thank you again for the kind comments!!

    I'm off for a business trip this week, but will get some updates next weekend. I plan to have the engine deck bonded together then.
    Thanks,
    Sean
  16. faustus100's Avatar
    Member Since
    Mar 2007
    From
    New York
    Messages
    316
    Oct 23, 2017, 6:30 AM - Re: 5 Foot Falcon Replica - ANH #41

    How did you get the curved acrylic hull? Loops amazing!!
  17. Member Since
    Sep 2010
    Messages
    392
    Oct 23, 2017, 8:45 PM - Re: 5 Foot Falcon Replica - ANH #42

    Thanks for the confirmation. Two sources are always better.
    I thought you guys were using magic tool to transfer anything on any surface, I was far from imagining something that "simple".
    No curve or contour gauge or anything. Let say you do not laser cut anything like in 1976.


    t2sides said: View Post
    Treadwell is right maxhebus! The rough contour is figured out, laser cut out of acrylic (for the walkways at least), then I use a combination of a belt sander and dremel to get the contour closer, then fine tune with varying grits of sandpaper. It's very much raw fabricating in order to get a flush fit. Particularly with making the bevel, all hand ground and sanded. Same goes with the cockpit tube, but with that fella, I cut a paper template, draw an outline on the tube, rough cut with a dremel, then fine tune again with dremel drum and then sandpaper. This is truly 'old school' hand labor, but the results are quite nice.

    Joberg and other folks, thank you again for the kind comments!!

    I'm off for a business trip this week, but will get some updates next weekend. I plan to have the engine deck bonded together then.
    Thanks,
    Sean
  18. Member Since
    Mar 2011
    From
    Jacksonville, Fla
    Messages
    84
    Oct 25, 2017, 8:29 PM - Re: 5 Foot Falcon Replica - ANH #43

    Sean,
    What are you using to cement the clear acrylic? Iíll be starting on the clear acrylic armature for the Excelsior soon. I bought a product that came from the place I bought my acrylic from - a water thin, and a thicker product. Just seeing what youíre using.

    Tracy
  19. Member Since
    Aug 2017
    From
    Iver, Buckinghamshire, UK
    Messages
    84
    Oct 30, 2017, 6:58 AM - Re: 5 Foot Falcon Replica - ANH #44

    that's amazing stuff going on there
  20. Apophis's Avatar
    Member Since
    Jun 2006
    From
    Fishersville, Va/Chulak
    Messages
    674
    Oct 30, 2017, 8:55 AM - Re: 5 Foot Falcon Replica - ANH #45

    Outstanding work Sean!
    I got a question, where did you get the domes for that falcon for that size? im looking for 32" for a falcon build of my own.
  21. t2sides's Avatar
    Member Since
    Apr 2005
    From
    Denver, Colorado
    Messages
    310
    Oct 30, 2017, 8:30 PM - Re: 5 Foot Falcon Replica - ANH #46

    Thanks!
    Tracy (Vidar), I use both the liquid and the gel Acrylic solvent. When bonding two larger flat surfaces, like 'plates', I use the thin runny stuff. For bonding say a 1/8" side wall to a flat surface, I use the thick stuff. They both work great. Make sure you don't use them with any styrene though, it'll melt it!

    Apophis and Faustus, I had the domes custom made by a skylight/plastics company. They are formed/blown from 3/16 acrylic to the specific diameter and height. It took about a dozen blows to get 3 good/accurate domes. (The company definitely lost money doing that for me, but they were committed to making it right for me). Because the tooling was too expensive, instead of going past the core, I chose to stop it at the edge, then will add the proper dome extensions. I had them 3D printed then cast (I'll post some pics soon of how those will accurately extend the dome and support the plating.)

    Here's the latest update. I have bonded the lower engine deck and the two lower Docking Ring walkways, and did a first shot of primer on them. I'll probably wind up priming the rest of the lower dome before adding more plating as it will be a light leak blocker (and follows the same approach they did back in the day)

    The bottom engine deck in place
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    The detail plate bonded down and dry fitting the engine extensions.
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    Walkways primed, bottom deck down with some plating started, and starting to dry fit the parts (Centurion Tank part rough cut)

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  22. faustus100's Avatar
    Member Since
    Mar 2007
    From
    New York
    Messages
    316
    Oct 31, 2017, 10:43 AM - Re: 5 Foot Falcon Replica - ANH #47

    Outstanding work,really stellar!
  23. Axlotl's Avatar
    Member Since
    May 2001
    Messages
    2,844
    Oct 31, 2017, 3:54 PM - Re: 5 Foot Falcon Replica - ANH #48

    This is awesome!
    How did I miss this?
  24. joberg's Avatar
    Member Since
    Sep 2013
    Messages
    5,206
    Nov 1, 2017, 8:40 AM - Re: 5 Foot Falcon Replica - ANH #49

    Beauty all around
  25. xenobiologist RPF Premium Member Leigh's Avatar
    Member Since
    Jul 2011
    From
    Cambs, UK
    Messages
    1,747
    Nov 1, 2017, 4:02 PM - Re: 5 Foot Falcon Replica - ANH #50

    Beautiful!!

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