Scaratch built 32" ESB Millennium Falcon

[JAWS]

Gday all. This is my first scratch build of any kind. I chose the Millennium Falcon as its one of my favourite ships & theres alot of refference material to help me out. To start with I had to find some Blue prints or Base Plans to help me get started with correct sizeing & shapes. The Millennium Falcon is a tricky ship to build because of its shape. I found some some Base Plans through this sites http://www.studioscale.com/thefalconmodels.htm forum http://groups.yahoo.com/group/MFalcon/
The plans are drawn up by Josh Maruksa & seem to be the most accurate available. During the search for plans I started collecting kits for the donor parts(parts used to kitbash detail) used on the studio model. There are quite a few & not all parts are 'confirmed'. I then had to get some sheet styrene(plastic sheet) to cut the base shapes & frame work from. I also needed new tools as I did not have any for this sort of work. So I had my plans, plastic styrene & tools ready to get started.

[JAWS]

The next faze of the project was transferring the base shape of the inner circle & mandibles to the sheet styrene. To do that I cut the shape of the falcon from the base plans I had printed up to size & traced the shape onto some paper I bought to cut the patterns used to mark & cut the styrene that will eventually become the frame of the build. Once I had traced the base plan from the base shape (The whole shape) I had to make an adjustment to correctly mark out the shape of the inner circle. To do this I mad a circle maker with a piece of wood with a hole drilled in one end to house a pencil & the other with a nail to mark the centre point of the circle. I measured the distance of the circumphrance (big word for circle) & then halfed it. Stuck a pencil in the half way mark, put the nail in the centre & traced around creating a smaller circle in the base shape. This is the centre of the falcon everything is built around with the mandibles attached. I then cut that shape out to mark on the sheet styrene.
                       

[JAWS]

Base shape with adjustments is traced to styrene for cutting. This was my first time cutting styrene & yes like the first time of you can guess what was a little shaky... Went to work & with a little bit of shoulder & some good advice from directorcass made the cuts, then bent & snapped the styrene in clean lines. The curves were my main concern though was happy to have them come away the same as a straight cut (thanks directorcass!). Before I knew it I had cut my first familliar shape & piece of styren at the same time. Just had another to do & we were in action. So followed the same procedure as with the first, just with a little added confidence! After a little effort we have twins

[JAWS]

All was good until my poor mathematical skills tricked me into thinking I need to make some adjustments I cut the mandibles in more when I did not need to. Tripple check & check again, then ask someone who has a better idea or knowlege than yourself so you don't have to do what I did. Start again

[JAWS]

Back to square 1 Next I cut some strips for the side walls of the inner circle & started to tape down to get an idea of how they should sit. I then sat the second half of the base shape to see how things were fitting & lining up. Its critical everything is at the rigt measurements to move forward on the build without faceing trouble later down the track, when it might be too late...

[Wombat]

Well mate,this piece is turning out just bloody awesome as i've mentioned elsewhere.What a piece to kick off your scratch building,and from what i can tell it's looking damn good bud.You've already made amzing progress with it and i'm sure you'll be back working on it again real soon.That's if some people stop pestering you about casting's i guess?

[JAWS]

Test fits removed. Imadding some 'electrical conduit' acquired from the Engineering Department at work. Waste not want not as they say. The 2 halves of the base shapes a taped together for some trimming to try & make them as identical as eachother as possible. I have to get some more supplies aswell. Locktite glue for 'glueing' the styrene together & some clamps to help hold pieces in place. The electrical conduit will act as supports for the shape to stop it from warping & for the wireing of the lights 'if' I decide to light this sucker. So trim trim the edges & hopefully start assembleing.

[JAWS]

Ha look who burrowed in! Nice to see you Wombat. Its a little bare in here at the moment but shouldn't take too long to get things back in order. Very happy to see you mate & very happy to try casting pieces for that 'Big' build you got in the planning stages. Hope you share that over here asell as the other boards (we can say their names, theres no rule about that. RI & The RPF are 2 more excellent sites to visit for modelling & refferences)

[Wombat]

Thanks mate,it'll be a pleasure to post that here when i get it happening.We both gonna have some fun with that one,that's for sure!
Until then i'll just have to browse around the place,but it won't be to long i hope and that new build will be a happening!!

[JAWS]

Won't not through lack of planning! Thats for sure.

[JAWS]

Time to start get an extra dimension to the srtyrene patty on my bench. So time to measure up some side panels etc & get the walls up. Everything was going damn well until one of my buddies(Mensaboy) informed me I needed to move the inside mandible walls in to accomodate the greeblies that run along them Yep so had to snap em off & I mean snap, once this Locktites dry in a matter of seconds its pretty much not going anywher unless you snap! Becuause I moved the inner walls in I had to move the conduit also, which really sucked since I went throgh all the trouble of cutting into a support structure to slide it through all snug & safe. It looked asthetically proffessional also But I guess no one will see it once the tops on.

[JAWS]

Moveing along to the side walls & theyre going up really smoothly. The Locktite really work fast so gotta make sure the piece is where you want it when you connect it. So all the walls went up pretty easilly & I now have a familiar shape really coming to existance. So exciteing to even just get this far on a scratchbuild. I put the top on for some more test fitting & everythings looking pretty good. Next fase will be to start working on the top section until I figure out the lighting system for this bird. Also have to honey cone the base with some supports for the top base to sit flat on & not sag. I fortunately salvaged some squre alluminnium rod from work that was just perfect. Waste not want yes I say This will be very sturdy support for a long time. i also have a couple of smaller guage pieces aswell that will reinforce the strength in the opposite direction. Im really happy with the progress.

[JAWS]

While Im still sorting out the lighting for the engine etc I will start on prepparing the supports for the upper hull dome. I cut a shape out from the Base Plan to use as a template for the curved support. I traced that onto some off cut styrene to use what ever I could & not waste any. I then cut that shape out with an exacto knife by running the blade along the lines, scoring into the styren. I then get the styren & bend it until it snaps in a clean line. Neat trick taught to me by 'directorcass., thanks again for that I then used the first piece as the template for all the other pieces. No matter haow much you try, unless this stuff is computer cut it will never be 100% the same as the last... Got em all cut & will now move onto secureing them in place with the Lock Tite glue. This is where my project has rested due to being robbed of my cameras in a house robbery a couple of weeks ago. I am please I have now been sent a replacement through insurance & can now continue with this project
           

[Wombat]

This is looking just great Jase.
You seem to have it all pretty sussed there mate.
This might,and probably is a stupid idea!But you could drill a couple of holes through those curve support pieces and put some bolt's through them to lock them all up together tight.Get your bottom and square end 's lined up when locking them up.Then you can sand the curved edge's of the styrene to get them all pretty much the same.I think that would work,but don't hold me to it!!

[dbhs]

Jase,

This is looking really good. Great progress shots.

Where are your mounting points going to connect to the internal frame?

[JAWS]

Thanks boys much appreciated. Its great to be back in action. Amazing how important a camera is... Doug, the reason I haven't cealed up the inner core is 2 reasons. Lighting & mounting points & to tell you the damn truth I forgot all about the damn mounting points! Thanks mate I could have nearly had a big F*%k up! Hmmm, mounting points....

[3d-builder]

Going to make one of these one day......so thanks for doing all the grunt work buddy!!! Will pick your brain on it for sure when I get there! To build your own Falcon is "The Deal"!!!

Regards,
Michael

[dbhs]

The mounting points will all need a strong connection to the frame capable of holding the whole model. There are some good examples of randy cooper star destroyers that have good frames. Different ship but I remember some used square aluminum tubing and may give ideas on connecting the mount point to the internal structure. Check out RI and RPF WIP for these.

[JAWS]

Ok Ive had a great day. Started with my second job at 2am this morning & then a trip with the wife, kids & 2 dogs(Staffy's) to the beach. Beautiful day & made the most of it cause when I came home in the garage I went & got to work. So I said Shuttle, mmm no, need armiture. SSd,mmm, no , need drill bits. So started casting some Replica Icons Deathe Star Bases for my first customer, who bought 3! Wow. Totally stoked. So Inbetween that I was looking at the poor Falcon thinking, yes you poor Falcon its time... So back on the MF I am. To tell the truth I was havn my ifs & buts about this but I immediately fixed a couple of things that were bothering me(measurements) & started honey combing the spaces to support the top layer. Ive also got a lighting plan & some supplies so decided to move forward with some wireing aswell. So heres what I did today in pictures,

[777]

Looking great Jase!

[JAWS]

(11-29-2009, 06:48 PM)777 Wrote: Looking great Jase!

Thanks mate. It was good to get this back in the line. Im really keen to get some more shape to this baby! Ive definately got plenty to keep me occupied.

[JAWS]

Can't leave it alone now Im back on it, besides my drill bits for the SSD aint come & neither has the armature for the Shuttle. Perfect! Sp today I cut the holes for the mandibles as I realised I haven't done that yet Anyway they were one of the blody hardest things Ive done so far! All went relatively well & their done so just sone clean up with the Demel & I'll box them in Got the lid on to check we're all good & Im pretty damn happy now cause I can start on the top dome

[Wombat]

I bet that was fun!

But ya over that bit now and it should be cleaned up by the next update?

I'm interested to hear what other may do to cut these sorta round hole's out.A holesaw come's to mind and maybe even scoring your way through with some sorta tool perhaps,i'm sure there would be something out there?

[JAWS]

Phil there is but I haven't been able to find it & funds are stretched with Christmas & paying for my Viper... Hopefully in the future I will be able to get the right tools. So I got back in there again determined to get a start on the top dome Im really happy with the work Ive done in the last 2 days. Everything is coming together real good. Check out what I ve done this afternoon. The supports for the dome sheeting are almost up. Ive left the nesseccary gaps for the wells to go in so I won't get hit with having to modify their location later. Big day & very happy. I'll pick up some 0.75 & .050mm styrene sheet on Wednesday to start sheeting the dome * maybe even get a start on the plating

[Damien9479]

(11-30-2009, 05:25 PM)Wombat Wrote: I bet that was fun!

But ya over that bit now and it should be cleaned up by the next update?

I'm interested to hear what other may do to cut these sorta round hole's out.A holesaw come's to mind and maybe even scoring your way through with some sorta tool perhaps,i'm sure there would be something out there?

There is a tool Phil....remember how I cheated my way on the 40mm gun tubs for the 1/350 North Carolina??
It's a circle cutter...compass cutter whatever the hell it is called!! LOL
And they are really cheap too

[Wombat]

^
Oh yeah that's right,that was the thing i was thinking of.
I wouldn't call it cheating though,it's a great idea for cutting out perfect circles.
Thanks for posting that Tom,i'm sure there are other's that'll find that tool useful also!

[JAWS]

(12-02-2009, 02:38 AM)Damien9479 Wrote:

(11-30-2009, 05:25 PM)Wombat Wrote: I bet that was fun!

But ya over that bit now and it should be cleaned up by the next update?

I'm interested to hear what other may do to cut these sorta round hole's out.A holesaw come's to mind and maybe even scoring your way through with some sorta tool perhaps,i'm sure there would be something out there?

There is a tool Phil....remember how I cheated my way on the 40mm gun tubs for the 1/350 North Carolina??
It's a circle cutter...compass cutter whatever the hell it is called!! LOL
And they are really cheap too

Thats the best picture I got of one of those things & I think the best description must be 'Compass cutter' cause when I said circle cutter to anyone they were WTF? Thanks for that ebay here I come when I get paid

[HadronMM]

Hi all. There's a variety of circle cutting gadgets at the arts and crafts stores like Michael's here in California in the section for scrapbooking and/or picture framing. Lots of little rigs like this for cutting circles in matte board, styrene, and so on.

Great to be on this board. I'm psyched about Jason's Millennium Falcon build.

Matt

[JAWS]

Hey thanks Matt. Its good to see you signed up. Be sure to write a helloo in the 'New Members Post Here' thread so everyone can introduce themselves & say Gday or hello. How about posting your R@ in the Props section I think its empty at the moment as the sites still in lift off mode but theres plenty of fuel getting pumped into the thrusters! Today i found some pipe that looked about right for my Mandible wells. Got the Engineers to cut them for me & theyre pretty much right. Maybe a thin layer of styren to seperte the 2 halves & we're sorted. Need to get 2 more cut tomorrow! Im picking up the 0.5 & 0.75mm styrene sheet tomorrow & will have some good progress on this over the weekend

[427 Cobra]

I'm glad to see that you haven't given up on this. I didn't know you had that Tyrell six wheeler,and Morser Karl! I need a couple of parts from each of those kits. I'll send you the email today. I've ID'ed all the kit parts I can from the available scans.

[JAWS]

Thanks Cris. Like I said just tell us which parts you need or think you need. If I don't have it or can get it one of the other members might.

[dbhs]

Looking good, Jase. Nice rings.

[JAWS]

Thanks. I cut some more today as the first ones were 5mm to big This pipe is just 1mm to big also but Im not that fussed. I might just run some styrene around the inside edge so that will be easy & I need to put some through the 2 halves to separate them. Getting there bit by bit. Just love building something from a drawing. Its really satisfying & exciting to see it come to shape

[Wombat]

Creating something from nothing is a lot of fun!

To me you are doing a great job on this Jase,it just blow's me away how you manage to deal with everything that ya got on ya bench.
Keep at it bud!!

[HadronMM]

Looking great, Jason. Every little thing you do, no matter how tedious, will pay off later.

So you must have thought about this: How are you going to rig up the mounting to a stand? Some sort of post that will connect to that superstructure you've got inside now? I wonder if some sort of multi-directional clamp base, like you use for soldering, might adapted to let you lock the ship into various positions when it is all done.

Matt

[JAWS]

Matt thats one of my next steps in the middle section. The mount & the internal lighting. I found these wicked bright LED strip, but theyre expensive. Well the ones I like are anyway. theres a cheaper version, just not as bright. Im now thinking I will make up a box & make my own for less $$$$ & most probably get the same affect. I picked up the rest of my styrene sheeting this afternoon. It was cheap too, stoked. I got 0.50mm, 0.75mm & grabbed some 1.00mm while i was at it cause it was cheap . Hope to have some good progress on this soon. its really just the guts of the build thats holding me up but its better to have done as best as possible the first time. I really don't want to be pulling this thing apart once I start putting kit parts all over it

[dbhs]

Looks good Jase.

I need to find a local source for sheet styrene. I just picked some up from Tap Plastics. The prices are good compared to the small modeling sheets but they only have 1/16" and 1/8" thick and no metric.

[Wombat]

Nice size sheet's!!
Don't let the kid's see them though,they'll think dad's bought em some new scribble boards!

[427 Cobra]

(12-09-2009, 07:19 PM)dbhs Wrote: Looks good Jase.

I need to find a local source for sheet styrene. I just picked some up from Tap Plastics. The prices are good compared to the small modeling sheets but they only have 1/16" and 1/8" thick and no metric.

I don't know where you live,but I get mine in 0.20" and 0.40" thicknesses - (the same that ILM used back in the day) from http://www.usplastics.com These are the cheapest I've found for sheet styrene in 6 foot x 40" inch measurements. They also sell hollow acrylic tubing,and solid acrylic rod from 1/16" of an inch to 8" inches in diameter. They also sell every kind of plastic you can think of including fibreglas. These rods,and tubing are only sold in six foot lengths.



Editorial note: Post edited for accuracy.

[JAWS]

These come in black also. They were 1520x1270 & $7.00 a sheet. You know Cris I shoulda got black & copied ILM! might just do that!

[427 Cobra]

I would've done it too,but I wasn't looking for black,as I'm not making a Falcon - otherwise,I would've. Frank Cerney used black styrene for authenticty. It's not too late - do it,Jase! Like I said before - they sell all kinds of plastic products there. You'll be surprised by what you see - I was!

[JAWS]

The chick at the counter gave me black at first. im going to go back & get some. For $7.00 a sheet its not going to break the budget. Can someone who owns a MR Falcon please take measurements of the Mandible wells(the circles) I need to know how deep they are? Please Please ahmmmm cough! cough! Wombats got one???

[Wombat]

It's a bit hard for me to get to the bottom one and i hate giving measurements out in case what i'm reading isn't really correct.
But for the top one's,NOT including the plating i get these figure's.
Forward Starboard one is 12.5mm to the top of what look's like coolshade perhaps?
Forward Port one is 11.6mm to the top of again what looks like it might be coolshade in there.
Aft Starboard i get 10.6mm,think that is the bottom of the well,no part.
Aft Port i get 11.6mm,again,think that is the bottom of the well and no part.
I'm not sure i'd trust any of those though as it was me doing the measuring!

[427 Cobra]

(12-12-2009, 07:25 AM)jasonwright.1972 Wrote: Can someone who owns a MR Falcon please take measurements of the Mandible wells(the circles) I need to know how deep they are? Please Please ahmmmm cough! cough! Wombats got one???

That's not subtle,Jase!

(12-12-2009, 10:33 AM)Wombat Wrote: I'm not sure i'd trust any of those though as it was me doing the measuring!

That's not true! After I saw your Cylon Raider build,I have the utmost confidence you do the modeling world more good than you realise. Do you have a dial caliper? It's what I use for measuring accurately. This ensures perfect numbers every time.

[JAWS]

I don't think the calipers will fit in the wells Cris.

[Wombat]

(12-12-2009, 10:58 AM)427 Cobra Wrote:

(12-12-2009, 07:25 AM)jasonwright.1972 Wrote: Can someone who owns a MR Falcon please take measurements of the Mandible wells(the circles) I need to know how deep they are? Please Please ahmmmm cough! cough! Wombats got one???

That's not subtle,Jase!


I guess ya can tell us Aussie's don't see the point of beating around the bush very much?

(12-12-2009, 10:33 AM)Wombat Wrote: I'm not sure i'd trust any of those though as it was me doing the measuring!

That's not true! After I saw your Cylon Raider build,I have the utmost confidence you do the modeling world more good than you realise. Do you have a dial caliper? It's what I use for measuring accurately. This ensures perfect numbers every time.

Hey thank's CC,they are some most kind word's mate!!
I like us all get a lot of inspiration at looking at other people's work's and these boards are the biggest part of all that.If my build's can be a part of that i'm most happy,i just don't see em as being at the level what the real builder's out there do.
Now,i had to look up what a dial caliper was.
It turned out to be what i was thinking it was.No,i don't have one,i just have a standard vernier caliper but worry that i was holdning it perfectly square.It was hard to get a spot that the plating on top and the part's in the well wouldn't interfere on the aft one's.
I just don't wanna be giving out wrong detail's,you can understand that i'm sure?
If Jase has some of the greeble's that go in them well's he can do some mock up's to see how those figure's look before applying to the Falcon itself!!

[JAWS]

(12-12-2009, 11:19 AM)jasonwright.1972 Wrote: I don't think the calipers will fit in the wells Cris.

yep i am a dumb ass sometimes. As Phil quietly pointed out. To measure in atight fit you use the opposite end of the slider to get the inside measurement

[427 Cobra]

First of all: Thank you for being here with us,and for sharing your excellent skills! Second: If you're at least making an effort to ensure accuracy by using a measuring device - that shows you DO care! As long as it touches the bottom of this tiny alcove to where it can go no further - Jase can extrapolate the rest with koolshade. This will give the dimension for the bottom with the added dimensions that you gave him with the koolshade. This will equal the overall depth of these two together. The other side of the Koolshade will HAVE to be the bottom of all these small alcove (inserts),or maintenance access ports.


Third: Your help is invaluable here. You are part of the team now.
I personally don't have any information on the Falcon,except ID'ing kits!


Finally: You'll be key to helping Jase with this build. This is what makes these forums great! I can make a tiny Chewbacca,and Han Solo for the cockpit with the dice hanging from the canopy,but that's all I can offer this build. I of course,need the measurements of the seat,and the cockpit if Jase wants these "little additions".

Jase,these calipers also have a bar that is intended to go in small places when it's extended. This is a machinists' tool. I'll post pictures to give you an idea of its' uses.
~ Cobra Chris

[Wombat]

Thanks again CC,i try but,there's always a lot of doubt in what i can actually do.Desire and dreams don't always help when you can't back em up with the skill's needed.With the measuring of those bit's i ws only able to get a small portion of the caliper end to sit on top,thus i'm worried that it may have not been sitting perfectly square with the bottom,but they will give him something to work from.So thank's once again mate,i feel right at home here and even though we are a small group thus far,we all have a passion for it!
That Han and Chewie figure sound's cool,i know there were some done at the RPF a while back but i wasn't a member at the time and couldn't get on the list.I'd also be interested in a set for my MR Falcon if you ever do decide to make em.
How one will measure the seats in there is a bit of a guess though?But i should be able to could come up with something close i'd think?

---

OK,Jase,i just looked at the sheet i wrote those figures on and noticed i gave them out wrong for Starboard and Port.
I've edited the post to correct that now.
Now ya see why you should have some working this stuff out that know's what they are doing!!

[dbhs]

(12-10-2009, 04:34 AM)427 Cobra Wrote:

(12-09-2009, 07:19 PM)dbhs Wrote: Looks good Jase.

I need to find a local source for sheet styrene. I just picked some up from Tap Plastics. The prices are good compared to the small modeling sheets but they only have 1/16" and 1/8" thick and no metric.

I don't know where you live,but I get mine in 0.20" and 0.40" thicknesses - (the same that ILM used back in the day) from http://www.usplastics.com These are the cheapest I've found for sheet styrene in 6 foot x 40" inch measurements. They also sell hollow acrylic tubing,and solid acrylic rod from 1/16" of an inch to 8" inches in diameter. They also sell every kind of plastic you can think of including fibreglas. These rods,and tubing are only sold in six foot lengths.



Editorial note: Post edited for accuracy.

Thanks for the info. They have great prices too.