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RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 02-10-2010
Ok so if I was to make a 'plug' I need to first make the shape by cutting the circle, build the curve with the supports, fill it with a foam or something, smooth it out & maybe cover with bondo & smooth/even out again right. Build vaccuum box, heat the plastic until it sags, put over plug thats sitting on my new vaccuum box connected to my Dyson Vaccuum & that should be it right in a nutted down version.
RE: Scaratch built 32" ESB Millennium Falcon - 427 Cobra - 02-10-2010
(02-10-2010, 05:02 AM)MonsieurTox Wrote: Glad to help Jase !
Flintlock, it's a good thing to have holes in the pattern itself, they dont need to be big... just 0.5mm or so is enough and it's almost invisible on the pull (and the hull is covered by the armor plates).
Chris, you're right, I plan to do a quarter half-hull plug. This way I'll need 4 pulls for the top hull and 4 for the bottom one. Unfortunatly my oven is too small, even for a quarter hull !
Yeah,Julien - you're absolutely right. This is the only way to do it without complications,or ruining your project. I can't think of any other way to do it with a conventional residential oven. This way,it'll have the strength you desire,and it'll still be easier to do than being way off with an unknown,or untested theory. You're pretty smart,Julien. You,and I are at least on the same wavelength here.
I just hope that this will give the best,and most satisfying results without having to tweak,or redo your work.
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 02-27-2010
Ok Im going to have the hull domes 'vaccuformed' by my plastics supplier. I need to make the plug. Can someone tell me what that foam stuff is everyone uses so I can fill in the ribs then sand, bondo, sand & get formed???? I think thats what i do. I got a basic idea. Guess I better search some threads...................
RE: Scaratch built 32" ESB Millennium Falcon - bwayne64 - 02-27-2010
(02-27-2010, 03:12 PM)jasonwright.1972 Wrote: Ok Im going to have the hull domes 'vaccuformed' by my plastics supplier. I need to make the plug. Can someone tell me what that foam stuff is everyone uses so I can fill in the ribs then sand, bondo, sand & get formed???? I think thats what i do. I got a basic idea. Guess I better search some threads...................
Jase, is this what your looking for. It's a two part expanding foam.
http://www.shopmaninc.com/foam.html
I've heard some people use the canned insulation foam, like "Great Stuff" brand also. I don't like the cans, cause once you use them once, they seal up. It's next to impossible to get a second use from them. The two part stuff is great cause you only mix what you need. Hope this helps, cheers,
Joe
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 03-10-2010
Hi crew well this build needed some attention & I need a break from the other things Ive been working on. Ive traced a full arc from a base plan which I then cut & used as a template to cut some more. i will cut probably another 4 aswell. These will be used to make the fram which I will fill with stuff(still unsure) that one of the engineers at work is going to help me with(ex boat builder). This will be the plug to get 1'5mm styrene sheet 'Vaccuformed into the 2 hull domes. I am getting my plastics supplier to do the actual 'Vaccuforming'. I do hope to build my own one day, but not right now. I'll update with progress on the filling & shapeing of the ribs soon. thanks.
RE: Scaratch built 32" ESB Millennium Falcon - 427 Cobra - 03-11-2010
This looks great! I hope that this means you'll be able to get this done before you have to go back to casting.
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 03-11-2010
Thanks Cris. Just want to get these Domes done. Should have had this all boxed up by now in all honesty. Just needed some thought time to figure out the best process to follow. I'll have to get back to casting on the weekend though to finish & fix some stuff.
RE: Scaratch built 32" ESB Millennium Falcon - scratchy - 03-11-2010
That is one build that I would like to attempt. Jason, If you where to put a scale to this build what would it be.... around 1/48?
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 05-09-2010
Howdy. Its been waaaay tooooo long since I gave this project some attention so when I got home from work this morning I went about glueing all the ribs to the base. Ive got them all glued down with the 'Weldon#16' great stuff & I won't be useing super glue any more. I will also go back over what Ive built & reinforce it with the Weldon. So the shape is there. I bought a bag of wall filler that I am going to use to fill in the ribs to build up the shape. Unfortunately this 500g bag aint even going to get close to doing the job & will need a premixed buckets worth at about $60 worth. This is going to be a costly exercise initself so better bloody well be worth it
RE: Scaratch built 32" ESB Millennium Falcon - 427 Cobra - 05-09-2010
How about Bondo at $10.00 a gallon? I know it stinks, and it needs to be mixed right, but it works, and it's a lot cheaper for the same job!
~ Cobra Chris
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 05-10-2010
Actually I think Bondo is more expensive here. I know Phil uses it. Maybe he or Mike can enlighten that for me & maybe also tell me the best place to buy it? I can get a 20Ltr tub of this for $50-60. Its non toxic, dry's fast & sands easilly. Its just to make the plug for the Vaccuforming so Im not being too fussy. This sort of stuff is more expensive in our country. Actually everything is...
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 05-12-2010
Had to work late & familly dinner at our house so didn't get this done tonight. I have the supplies & am keen to tackle this task. I have a can of foam filler that I will spray between the ribs to fill them. I will then use a box cutter to cout away the excess. I will then use this Polimer Putty to fill over the foam & smooth off. After all this is done I will sand down to the required shape. That I hope will give me a nice 'plug' to take to the plastics shop & have vaccuformed into 2 nice dome hulls for the Falcon.
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 05-13-2010
Ok so got home went for a walk with the kiddy's & got straight into it. I really have no idea if this will work. I saw Sean C a very good modeller doing something similar with the foam though was a different product etc. the method is sort of the same so my mind is telling me this will work
Ive sprayed between all the ribs with the filling foam & it looks pretty bad right now. the plan is to come back when its cured & hopefully a box cutting blade will cut through the top along the ribs giveing me a roughly filled in dome shape. I will then come over that with the Poly Potty to fill in all the areas the foam didn't & give it a coate. After that has set I will sand it all down to the ribs & will then hopefully have a full shape which should be the plug for the Falcon Domes to get vaccuformed
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 05-13-2010
The foam has started to cure & has expanded more filling in all the space
Pretty kool stuff! I think this may just actually work 
RE: Scaratch built 32" ESB Millennium Falcon - 427 Cobra - 05-13-2010
That's what we use for insulation. It works real well for boats, and floating craft. Just be careful not to get it on anything you don't want ruined.
~ Cobra Chris
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 05-14-2010
Cris yeahthis stuffs sticky! So started cutting away at it last night & realised the centre hadn't cured. It had formed a crust over the top & the centre had stayed sticky & uncured. i cut some pockets to let the air in & left it over night. I got up this morning & gave it a bit of a bash. I used a hack saw blade & sawed through it. It was pretty hard going believe it or not. I now realise I could probably have got a better result using less foam & just let it expand. I guess we gotta learn some how & Im not unhappy with the results. A bit more shapeing & then can fill in the gaps & create a smotth coate with the poly filler. This is sorta fun in amoungst the stress of waiting for failure & success. Stay tuned.
RE: Scaratch built 32" ESB Millennium Falcon - dbhs - 05-14-2010
Whoa !!!!
Very cool. Throw some choclate sprinkles on there and eat it !!!
I think thats' going to work really well actually. with the putty on top it will be plenty strong for vacume forming the dome. Using the hack saw blade to trim it down was a good idea too.
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 05-14-2010
Yeah the hack saw blade worked pretty good. When you hit the ribs you just keep hackin & it travels along & down. im actually quite impressed with my mess. You should see my garage!
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 05-14-2010
Well just got some negative feedback from this path I have taken from a modeler who's knowlege & opinion I trust. says his stuff may explode with the heat & pressure from the vaccuformer... Not sure what to do now.
RE: Scaratch built 32" ESB Millennium Falcon - dbhs - 05-14-2010
Unless you're doing a pyro model, not a good idea !!
Did he have any suggestions for alternate foam products that are not flammable? The expanding foam seemed to work pretty good filling the form. You could use a sheet foam and fill in the gaps but that will be a lot more work.
RE: Scaratch built 32" ESB Millennium Falcon - 427 Cobra - 05-18-2010
This stuff won't explode, but it will burn if it gets too hot! Not a good idea if you don't want a huge fiery mess on your hands, and inside your oven. I'd just glue the styrene sheets over this, then put it together as you would've before.
~ Cobra Chris
RE: Scaratch built 32" ESB Millennium Falcon - Wombat - 05-18-2010
Jase,i think what Chris said is something to think about doing perhaps.Honestly,after seeing what Doug did with the CR i can't see you having a problem either if you went back to that way yourself.I guess it's really upto you if you want to go and make all that again really?But it probably won't look any different in the end either way?
RE: Scaratch built 32" ESB Millennium Falcon - MonsieurTox - 05-19-2010
Well I dont think it would explode but the Polyfilla would crack for sure ! You ant something stronger like bondo if you want to do more than one pull
I wasnt very satisfied with the pie-way of my MF, at this size (an considering you want a thickness of about 1 mm), it would be too soft (mine was 1.5mm and it was too soft). Plus, it's a headhache to sand it to get very nice curves and not a ribbed saucer lol
The vacformed hull is the best for this job IMHO, you just have to find a way to make a plug strong enough to make at least 2 pulls, but as I told you, ask Neil (Vos) on the RPF, he does his plugs with insulation foam sheet, the strong one, ask him for the density. That's how he did the Lambda Shuttle. And he doesnt even used bondo (but I would to get a nice surface !
).Dont give up Jase, I know that's some work, but you wont be disapointed once you've got your vacformed hull and when you'll see how strong it is... and with nice curves
You would probably not put your almost finished Falcon in the trash as I did.
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 05-19-2010
Julien thanks buddy. I won't give up. Its just not in me. I'm going to have another crack at this. I'll use 3mm styrene for the ribs & either the modelling clay or 2 part foam mix. I want to make something that will last so if anyone else wants a set i may be able to do it. The main thing is getting at least one set for my build though. I'll be back on this soon. Im in no rush. Ive only been attempting this sort of modelling for just over a year no so have lots to learn still.
RE: Scaratch built 32" ESB Millennium Falcon - jon pollock - 05-20-2010
I have a lot of respect for you boys... it's almost like watching the wheel being invented.... or super abilities to recognize certain parts from other kits that make up a star destroyer. I honestly can't believe it at times, but then realize it's the passion (or obsession) that drives you/us... crazy I'm sure at times. I've recently had to put the styrene down for lack of time (newborn son) and must live it through you. So thanks, and keep up the jaw dropping work. Maybe sometime in the future I'll get my HMS Hood or Cylon Raider done to the point of showing. I'm not holding my breath tho...
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 05-20-2010
Thanks Jon. Where all here to help with anything you need regarding a build or anything else actually. These are great communities with great people. welcome to the board & thanks for the feedback. Don't be shy in showing us what you have.
RE: Scaratch built 32" ESB Millennium Falcon - jon pollock - 05-27-2010
I'll see what I can do about getting some shots of the Raider up here. THX JW
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 07-08-2010
Just moved this into here. Nice new home for this project. Has been onthe bench for a while & need to get the domes sorted to progress. May even start again with the new skills Ive picked up & the kool buddies that want to build this properly. Update coming soon.
RE: Scaratch built 32" ESB Millennium Falcon - MonsieurTox - 07-11-2010
Cant wait !!!
RE: Scaratch built 32" ESB Millennium Falcon - scratchy - 08-28-2010
I don't know if I'm too late for any constructive input,.... but have you considered modelling clay for the piece that you use to vacuum form over?
It can be found in most artist supply stores, I've got a box of it. Now, I haven't tried it yet, just throwing ideas out there.
Jason, I really like what you're doing with your 32" Falcon, it's inspiring me to do research on this build, I already have a kit list in the works and I'm just confirming it with Phils, Juliens and your build threads.
Keep going, looking forward to more updates!!
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 08-28-2010
Scratchy I could go that route but I am getting one digitally cut from MDF. I will then offer some out for those that may want to build this some time. I will be getting it done sometime soon. Also researching some more before continuing also. Feel free to post ideas & questions.
RE: Scaratch built 32" ESB Millennium Falcon - 427 Cobra - 08-28-2010
(08-28-2010, 04:06 PM)jasonwright.1972 Wrote: Scratchy I could go that route but I am getting one digitally cut from MDF. I will then offer some out for those that may want to build this some time. I will be getting it done sometime soon. Also researching some more before continuing also. Feel free to post ideas & questions.Sure you won't - I could've built ten falcons by now! Everyone's already ID'ed just about all the parts on it. It's a basic circle with a right angle tunnel, and two ramparts on one end! I'm still dragging my feet because of finances, and parts availability. That Galactica's thousands of dollars, and months if not years away from being finished. I was hoping the Falcon would be the priority, and we'd be seeing a finished model by now.
I understand researching, but without anyone else doing the same to help speed things along - it's a very long, and lonely search.
I'm past the researching now, and I only need to cast parts. Once all that's done, it'll be smooth, and quick sailing to the end before cold weather sets in. Hasn't everyone else here noticed that there were no four foot X-wing parts, or talk about a four foot X before I posted mine with the correct dimensions - now everyone has a laser canon, and engine housings for them AFTER I posted them on studioscale modelers, and the rpf last year?! I'm the only one doing ALL the research, and modeling - everyone else is riding my coat tails as I post more, and more updates with new parts, which is why I don't want to post on the other forums now. The falcon's been done, which is why I didn't choose to make it, or another "studio scale" X. 
Honestly, Jase - I wish you'd just finish the Falcon before doing any other projects. I was really hoping you would've been done by now. That thread was on fire for a while until the Galactica discussion on RI ruined all hope of seeing your Falcon project come to fruition before the end of the year. I've had other modeling projects for other people, and personal problems get in the way, but I'm still prodding along - slowly, but surely. I've also had projects that needed to be done that took time away, and that killed my fire for modeling....
I need your strength, Jase - I'm the only one making Star Wars models other than, Scratchy, and Tox. Theirs aren't going any faster than mine. ~ Cobra Chris
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 08-28-2010
Theres no rush Cris & Im still learning. My bilds have slowed down mainly due to bills. This hobby is expensive & drains alot of finance. The kids suffer sometimes & Ive been giving more time & money to making them happy. Its not about the money but it helps to do fun stuff. The Falcon will get done & when it does it will be done right. There are more people than myself working on the research as this model is far from 'correctly' & 'Positively' id'd. The MR Falcon was certainly not 99% covered in 'actual' kit parts thats for sure.
RE: Scaratch built 32" ESB Millennium Falcon - 427 Cobra - 08-29-2010
I thought MR did the "ultimate job" accurately recreating this according to the members of the rpf. They were all ooohing, and aaahing it when it was first released. That would explain why so many of them are now building their own Falcons from scratch. I figured with as much jibber-jabber about the parts ID, and http://www.studioscale.com that they had just about every nook, and cranny nailed down, except for a few! I understand the family situation, but what inspired this "Galactica renaissance"?
~ Cobra Chris
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 08-29-2010
It was one of the things that brought me to the modeling scene. Jim Crevelings. Its just one of many builds I will attempt. Just had a good opportunity to work with Phil on it & jumped at it. Once I get these hull domes done things will pick up again. I also want to build a 44"Eagle amongst the other SW's builds. This is just my forst year of studio modeling. Im just getting warmed up Cris!
RE: Scaratch built 32" ESB Millennium Falcon - Brundelfly - 08-31-2010
Back to gluing stuff.
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 08-31-2010
Note# I have deleted posts that were of conflict after the event was finished. I want to remind all members that insults to other members, sites, companies inything are not permitted. If we have nothing nice to say don't say anything at all. What doesn't offend you, may offend somebody else.
RE: Scaratch built 32" ESB Millennium Falcon - 427 Cobra - 10-04-2010
I don't know if you're going for absolute accuracy, here's the site where you can get small black sheets of styrene for your Falcon. I guess they originally used these in the old ILM shop so they could see the overlying plating details over the black superstructure. This would account for accuracy when duplicating the five foot model.
~ Cobra Chris
http://www.micromark.com/BLACK-STYRENE-PLASTIC-11-WIDE-x-14-LONG-x-060-THICK,8573.html
RE: Scaratch built 32" ESB Millennium Falcon - peza - 07-10-2012
eh up buddy just been lookin at ya build and i`m really impressed mym8,i`ve not evan fought about seelin up the back end where me lights are goin. do ya know anybody that`s used E.L. tape for the engine lights?
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 07-10-2012
Ha! I was just thinking about this thread when I saw Aurora's build post.
Thanks for the kind words.
If I continue this project I will definately start again as it was my first at trying to scratch build anything.
I would also go 5ft rather than 32".
RE: Scaratch built 32" ESB Millennium Falcon - darkimmitator - 07-10-2012
Go big or stay home , eh Jase !!! lol I believe the famous Movie phrase " Your gonna need a BIGGER boat ' comes to mind .lol
RE: Scaratch built 32" ESB Millennium Falcon - peza - 07-11-2012
eh up jase have you anymore images of ya build mym8,what lightin have you desided on,i`m very tempted on usin E.L. tape
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 07-12-2012
(07-10-2012, 09:57 PM)darkimmitator Wrote: Go big or stay home , eh Jase !!! lol I believe the famous Movie phrase " Your gonna need a BIGGER boat ' comes to mind .lol
Hahahah
I ove that line.I think I just wanted to tackle my all time favourites first.
Especially with all the work Gort & the boys have done at the http://www.therpf.com/
Peza I'll dig something up but I think I posted most pictures.
RE: Scaratch built 32" ESB Millennium Falcon - Aurora - 07-28-2012
(07-10-2012, 05:33 PM)jase72 Wrote: Ha! I was just thinking about this thread when I saw Aurora's build post.
Thanks for the kind words.
If I continue this project I will definately start again as it was my first at trying to scratch build anything.
I would also go 5ft rather than 32".
I haven't touched mine in ages. Thought I try an easier build been working on the tie bomber an that's still not done. One day though I'll have a falcon
RE: Scaratch built 32" ESB Millennium Falcon - JAWS - 07-29-2012
Yeah an update would be great.
Myself am going to build a 5'er rather than the 32" first, later down the track off course.
RE: Scaratch built 32" ESB Millennium Falcon - peza - 08-02-2012
eh up buddy,i know your pain,im workin on a shoe string budget cos of the familt life thing,but wouldnt change it, the kits and everything would be nice but hey there smiles are better.i proper have deep respect for anyone who can make the models you boys make, i just feel like the poor relative sometimes,but inspired all the same,just remember theres people out there who are prepared to help if they can.never give in,never surrender! cheers peza.......
(07-12-2012, 06:39 PM)JAWS Wrote:(07-10-2012, 09:57 PM)darkimmitator Wrote: Go big or stay home , eh Jase !!! lol I believe the famous Movie phrase " Your gonna need a BIGGER boat ' comes to mind .lol
Hahahah
I think I just wanted to tackle my all time favourites first.
Especially with all the work Gort & the boys have done at the http://www.therpf.com/
Peza I'll dig something up but I think I posted most pictures.
RE: Scaratch built 32" ESB Millennium Falcon - THX1701 - 02-05-2013
I took the plans into a print shop today.They were able to make the Top and bottom view at 32 x 24 but for all the side views I was telling them to print the side at 32 in and the front and back at 24 but I don't know what to tell them about the height. What should I tell them?
RE: Scaratch built 32" ESB Millennium Falcon - joewhite - 02-06-2013
I don't have the height measurements on me but can't they just print them 1:1?
Joe
RE: Scaratch built 32" ESB Millennium Falcon - THX1701 - 02-06-2013
(02-06-2013, 03:42 AM)joewhite Wrote: I don't have the height measurements on me but can't they just print them 1:1?
Joe
I asked an they didn't seem to understand what I was saying. Unless anybody knows or has an Idea, I will try a few other print shop. I thought I read at some pint in time, that it's 5 1/2 inches at it's thickest point.
"I'm not afraid of heights. I'm afraid of widths."
Steven Wright-
RE: Scaratch built 32" ESB Millennium Falcon - daverep - 02-06-2013
I've got Joe's plans...and Maruska's drawings that Jase is working on in this thread. I probably can help. What measurement exactly are you looking for?