Not posted in a long time, but just got an email from a friend (TK818) who has also not been here in a long long time and lost his password/login during the last move. So he asked me to post this for him. He made a bowcast 3 or so years ago to go with his chewie costume.
Pictures are his (sorry about size), and I've not got any more information than this. He'd post himself but registration is turned off right now.
So here's TK818 / Richard message -
My thoughts at the time were that the overlapping discs could be hat discs flipped bottom side up allowing for an overlap.
That's what I did on my Caster with the rest of the panel bits consisting of washers, amp knobs and fabricated discs.
I used a Barnett Xbow for the base, hollowed out the solid stock and smoothed out the hand grips.
I had to fabricate the bow using heated Lexan with aluminum strips to give it rigidity.
The sling in the pics is an ESB sling, I haven't found a sling yet with the proper ANH hardware.
Here are the links for the Bowcaster Pics: