I’m thinking the same route. I’m still in the waiting process because I don’t have all of the stuff I ordered. Still waiting to see how this plays out.
 
I’ve had luck with a product called “Good Stuff”... picked it up from Lowe’s for about $5 per can. It’s a spray foam that you can use on the inside of your castings to add rigidness but little to no weight to the part. It also takes liquid nails as well as epoxy resin surprisingly well. Hope that helps some :D
 
I’ve had luck with a product called “Good Stuff”... picked it up from Lowe’s for about $5 per can. It’s a spray foam that you can use on the inside of your castings to add rigidness but little to no weight to the part. It also takes liquid nails as well as epoxy resin surprisingly well. Hope that helps some :D


This is what I ended up using. It worked pretty well and definitely added some strength to the Han. Thanks!
 
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A little more work completed. I have put a ton of bondo on the outside trim and been sanding it out.

I usedsome foam from Lowe’s to fill in the main areas of Hand hands and face. The foam is “good stuff” from Lowe’s. Propreplicator2 mentioned it above.
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I filled in the hands and face before mounting down the cast.

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I have mounted han to the box and filled him completely with the foam. This step really made him more sturdy. It also helped with adhering him to the box.

I started by mounting the legs.... then filling with foam.... let it dry.... then cut away the access.
I then attached the body to the legs and glued and screwed it to the box.... then filled with foam..... let it dry..... cut away the access.
Then the head.... same idea.

It went smoothly but I need to let everyone know..... use only about half of the foam you think. It really expands:)
 
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Finished up some bondo around the frame. I took several days of just bondo and sanding to try and make it smooth. It still ends up with small marks in the bondo that are tough to sand out.

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I also started sealing the 3 peice han together with bondo. I basically just used a gloved hand to fill in the gap. This will take a few coats and lots of sanding also but it seems to be working pretty well.

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This is fully sanded/bondo/and primer. I used
9EA5E687-467A-4DBC-832B-5FB8AE342129.jpeg rustoleum filler primer. It is sandsble and filled in the little imperfections pretty well. Then use a 350 or higher sand paper. Worked pretty well.
 
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Some painting and sanding done.
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The han I received had a very poor coating of primer on it. It started scratching off pretty easily so I decided to sand it down and re primer it.

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This new primer coating is really thick and coats it very well. It’s the same grey rustoleum primer as earlier.

I have pur 2 coats of the box color on. I plan to sand it smooth and put at least 2 more coats on.
 

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This seem is from puting the han pieces together. I’ll need to sand it down when the glue is all dry and the carbonite is in place. It’s all done with bondo.
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This is the han after several days of the glue. It is taking a loooooong time to dry.
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This is a photo of the seem I’ve already sanded down and primed.
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A view of the hero panel in place.

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I had to create a heat dome and place a heater inside to hopefully mold the glue faster. It’s been over a week.
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This seem is from puting the han pieces together. I’ll need to sand it down when the glue is all dry and the carbonite is in place.
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This is the han after several days of the glue. It is taking a loooooong time to dry.
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A view of the hero panel in place.

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I had to create a heat dome and place a heater inside to hopefully mold the glue faster. It’s been over a week.
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I like the glue video! Thanks for sharing that, how many gallons of glue do you think you will use?




Sent from my iPhone using Tapatalk
 
Fixed.

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I’m on the 3rd gallon right now. Looking back I should have used a 1/8 cutout if wood around han to lift up the deck. But so far I’m really happy with how it’s coming along. Just waiting for it to dry and add the minor carbonite effects.
 
How long are you waiting before adding the next gallon of glue? Does the glue harden completely before the next batch or is that part of the magic that creates the texture?
 
How long are you waiting before adding the next gallon of glue? Does the glue harden completely before the next batch or is that part of the magic that creates the texture?

This is a excellent question, I too would love more details on how to apply the glue

The glue applying is the scariest part for me
 
It’s an awsome build, but hard. You will be very satisfied once it’s over.
Hese are a few pics of my build:
http://nbg-studios.com/hic.html

great build!!

How did did you paint the recessed parts of the panels? Did you hand paint it or spray and tape everything? I’m thinking of cutting it out and gluing in some actual sheet metal.

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This is a excellent question, I too would love more details on how to apply the glue

The glue applying is the scariest part for me

I have more pics and video of the gluing I’ll add soon. I waited for each layer to dry, sanded it down a bit, and added the next layer.
 
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This is after several days in my garage with the heater on. It really didn’t settle fast so I brought it into my basement for more even heat.

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This is just before I added my second coat. I did a bit of sanding prior to laying the next layer.
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As others have stated, thank you for the actual video of glue application. Have been wondering about best ways to accomplish this. Looks like it is working out well?
 
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