Page 1 of 3 123 LastLast
Subscribe
  1. jacob4581's Avatar
    Member Since
    Oct 2009
    Posts
    44
    Nov 4, 2009, 2:08 AM - Han In Carbonite #1

    After millions of questions and pre-planning I'm finally getting started on my HIC. I am going to build a wooden box with 1x2s so it's a little lighter, and some thin pvc tubing for the rounded edges. I'm going to build the box 1/4" shorter than the blueprint to compensate for the 1/8" Sintra I am cementing and screwing on top of the wood. After it's all built I'll spray Han with some Pactra Indy Silver spraypaint and then Rub N Buff the Sintra for a metallic look. I took Friday off and I'll be building this thing all weekend, so expect a lot more posts and pictures soon. Thanks again to everyone here at DH and the HIC Builders Club, especially miqt and Stormrider, who helped me out and answered all of my questions. Just getting started but lots more to come after this weekend.


    I cut the extra rubber around the edges of Han with a pair of scissors
    making sure that the measurements matched up as close as possible
    with the blueprint.

    Click image for larger version. 

Name:	DSC00003.jpg 
Views:	581 
Size:	664.9 KB 
ID:	37874


    Then I cut the 5 pieces of Sintra with a Stanley utility knife according to the dimensions of the blueprint.

    Click image for larger version. 

Name:	DSC00004.jpg 
Views:	477 
Size:	663.8 KB 
ID:	37875
  2. Stormrider's Avatar
    Member Since
    Aug 2007
    Posts
    2,271
    Nov 4, 2009, 6:58 PM - Re: Han In Carbonite #2

    Im doing some research at the time being. Trying to determine some things. One is whethere my copy of the HIC is too trapezoidal (wider at the bottom). So you may want to trim it square.

    I would do the entere thing in the same color. Either all black, and then rub and buff the entire thing. Or all primer then silver, but I wouldnt do two different things on two places. It will not work out the way you want it. The entire prop should have the same color, just smoother on the outer box.
  3. jacob4581's Avatar
    Member Since
    Oct 2009
    Posts
    44
    Nov 4, 2009, 8:22 PM - Re: Han In Carbonite #3

    When I cut the extra rubber off I trimmed along the outer edge that was visible. I measured the top and bottom and they matched the slight trapezoidal dimensions of the blueprint. The main sheet that I'll mount Han on is still rectangle right now but I'll probably trim it to match the blueprint. Kind of a weird shape though. I bought four 3oz. cans of that Pactra Indy Silver, that's all they had at the Hobby shop. Do you think that will be enough to cover the whole thing after I prime it?
  4. Stormrider's Avatar
    Member Since
    Aug 2007
    Posts
    2,271
    Nov 5, 2009, 9:55 AM - Re: Han In Carbonite #4

    Yes I think so. If I were you though, id take some extra sintra, some extra rubber, and some primer, and do a mini mockup to make sure you get the effect your expecting.

    Im not saying you wont, its just nice to be sure

    Also, some expandable foam would work well to firm him up.

    Maybe buy a can of that, and spray a little spatchala it onto some of the spare rubber, and see how it works out.
  5. Stormrider's Avatar
    Member Since
    Aug 2007
    Posts
    2,271
    Nov 6, 2009, 6:33 PM - Re: Han In Carbonite #5

    Im sorry to say, my rubber didnt show up again today. So the three people that have paid, and are waiting, it will be monday at the soonest before I can start on them.


    Im sorry for the delay.
    Mike
  6. Member Since
    Jun 2009
    Posts
    98
    Nov 7, 2009, 2:58 PM - Re: Han In Carbonite #6

    Right On! You've started -thats great. Looks like you're off
    to a good start. I'll watch this thread like a hawk. If you
    use some 'great stuff' foam or what not -let us know how it
    works with this rubber. I'm thinking about taking some RE
    magnets and scrap styrene, drilling a couple big holes in the sheet
    plastic (to allow for the low expansion foam to escape).
    Magnet the plastic (with tin foil layer) to the HIC, spray the
    areas to be filled and remove the plastic after a few hours.
    Cant wait to see your continuing progress!
    Mike
  7. jacob4581's Avatar
    Member Since
    Oct 2009
    Posts
    44
    Nov 9, 2009, 1:43 AM - Re: Han In Carbonite #7

    Got some work done on this over the weekend at my Dad's new garage he built, he just retired and I'm envious . It was cool for me to work on a father & son SW project, and I could tell he was excited about helping out with it. Surprisingly all the supplies only cost me about $65. Started off with 3 1x10 8', 4 2x4 7', 2 2x4 6', 4x8 sheet of masonite, some 2x8 flat wood screws and #10 3.5" flat wood screws, Great Stuff expandable foam-yellow lid not the red, 3 8' pieces of 1/2" quarter round, a bucket of Natural colored wood filler, and some Liquid Nails.

    Click image for larger version. 

Name:	DSC00005.jpg 
Views:	321 
Size:	564.8 KB 
ID:	37960

    Click image for larger version. 

Name:	DSC00006.jpg 
Views:	276 
Size:	634.2 KB 
ID:	37961

    We pre-drilled some holes in the 2x4s that we cut to line the tops and bottoms of the 1x10 frame so that they could be set up to add the quarter round. The frame has a weird shape since it's shorter on the top than on the bottom, but it will be nice and sturdy...and heavy too haha.

    Click image for larger version. 

Name:	DSC00008.jpg 
Views:	281 
Size:	581.7 KB 
ID:	37962

    Click image for larger version. 

Name:	DSC00010.jpg 
Views:	305 
Size:	510.2 KB 
ID:	37964

    Click image for larger version. 

Name:	DSC00009.jpg 
Views:	291 
Size:	488.5 KB 
ID:	37963

    Then I measured the spacing for Han to lay on the sintra sheet I had cut before. Surprisingly when I cut the excess rubber off I followed the outside line or frame edge that was semi-visible and it was almost right exactly on size with the blueprint. I centered Han on the sintra and then traced a line around him so he would lay perfectly inside it. Then cut that out to make a frame for him. I also cut the sheet of masonite to size too. Here is a pic of the sintra frame, Han, and the masonite setting unmounted on top of the box. Making sure everything lined up good, I don't even think I'll need that much filler since he fits so perfectly in the frame. The 1/4" sintra is almost the same height as the rubber mold too.

    Click image for larger version. 

Name:	DSC00013.jpg 
Views:	447 
Size:	577.7 KB 
ID:	37965

    Next I taped the templates I posted in the Building an HIC thread to the sintra side pieces. I cut them out along the top and bottom edges that are included on the templates and just aligned them across the top. This way they'll all be along the same line since the bottoms of the pieces may have to be trimmed or sanded a bit. Just a note too on the panel sides if you are building a rectangular HIC instead of the ESB trapezoid remember to come in 5.25" from the side to start the first panel shape, then go 1' 7" from center to center. This compensates for the extra inches for the trapezoid angle shape.

    Click image for larger version. 

Name:	DSC00014.jpg 
Views:	302 
Size:	564.8 KB 
ID:	37966

    Then I cut the shapes out with my Stanley craft knife and used some medium grit sandpaper to smooth all the inner edges.

    Click image for larger version. 

Name:	DSC00015.jpg 
Views:	302 
Size:	542.2 KB 
ID:	37967

    Click image for larger version. 

Name:	DSC00016.jpg 
Views:	398 
Size:	563.7 KB 
ID:	37968

    And last we used Liquid Nails to glue the sintra pieces to the frame. I am getting some panels to put on this thing too but didn't want to bore out the shapes on the top and bottom. I thought it would look cool to at least have the shapes cut out where they would be and then paint over it. Here it is drying with some 2x4 scraps weighing it down.

    Click image for larger version. 

Name:	DSC00018.jpg 
Views:	361 
Size:	664.3 KB 
ID:	37969

    So really all that's left is attaching the quarter round for the rounded corners, mounting Han and drilling holes to let the foam escape, and then painting it. It's funny what you said about the expandable foam Mike, we both had the same idea about it. There is a little gap we'll have to fill on the face of the HIC to meet the quarter round but other than that it all matches up and lines up good. I should hopefully have this thing done by Thanksgiving, I'm going to an MU game on the 21st and then I'll be back home for Thanksgiving. Should be able to get it nailed down in a couple of weekend trips to Missouri.
  8. Member Since
    Jun 2009
    Posts
    98
    Nov 9, 2009, 6:48 AM - Re: Han In Carbonite #8

    Thats some impressive progress for a weekend!
    Tell your dad -Nice Workshop! I think Ill be having
    to build my HIC in our bedroom this winter.....I
    wonder what wifey's going to say about that?
    Mike
  9. jacob4581's Avatar
    Member Since
    Oct 2009
    Posts
    44
    Nov 13, 2009, 4:54 PM - Re: Han In Carbonite #9

    Got my panels and greeblies from Angela and Dung today, and all I can say is
    WOW . These are absolutely amazing, the details are awesome and it came with a perfect side by side comparison of the panels and individual envelopes that hold each panels set of greeblies. It even came with the decals too!! Now it's time to get started on painting these guys and maybe a trip to RadioShack to fit and research my electronics. I'm wondering if I'll need to bore out an angle inside the wood where the panels will be mounted. I couldn't tell if specs were mapped out on the blueprint or not. I know I'll be using an old light table's opaque white plastic top for the underside of the hero panel. Then I'll probably buy some sheets of reflective, mirror-styled material to line the insides of the other panels.

    Click image for larger version. 

Name:	DSC00019.jpg 
Views:	450 
Size:	559.7 KB 
ID:	38037 Click image for larger version. 

Name:	DSC00022.jpg 
Views:	398 
Size:	248.2 KB 
ID:	38038

    Click image for larger version. 

Name:	DSC00023.jpg 
Views:	377 
Size:	485.1 KB 
ID:	38039
  10. Fett4reaL's Avatar
    Member Since
    Aug 2009
    Posts
    337
    Nov 13, 2009, 5:30 PM - Re: Han In Carbonite #10

    ill take 2
  11. Member Since
    Sep 2008
    Posts
    9
    Nov 14, 2009, 7:03 AM - Re: Han In Carbonite #11

    Looks great so far Do you mind passing on the info on where to get the side panels from? I'd like to buy a set.

    Cheers,
    Rob
  12. Member Since
    Jun 2009
    Posts
    98
    Nov 14, 2009, 8:05 PM - Re: Han In Carbonite #12

    Wow, Im impressed. They're even prioviding a set of Glen's excellent
    alien script decals! I have those panels too and I love them....of course
    mine didnt come with decals :-)
    Really looking forward to your progress Jacob!
    Mike
  13. dsonik1's Avatar
    Member Since
    Oct 2009
    Posts
    1,492
    Nov 14, 2009, 10:34 PM - Re: Han In Carbonite #13

    I'll be watching this one from here on out.
  14. pigeonfarmboy's Avatar
    Member Since
    Oct 2009
    Posts
    128
    Nov 15, 2009, 6:12 PM - Re: Han In Carbonite #14

    Email dnanguyen@yahoo.com for the panels. I was surprised how quick the turnaround time on these were for me.
  15. Astro Builder's Avatar
    Member Since
    Jul 2009
    Posts
    306
    Nov 15, 2009, 6:57 PM - Re: Han In Carbonite #15

    Holy **** that's cool. I don't know why I am continually amazed by TDH members skills, but I am. Nice work.
  16. Ogait-Nas's Avatar
    Member Since
    Jul 2009
    Posts
    388
    Nov 16, 2009, 2:13 AM - Re: Han In Carbonite #16

    Outstanding work. Keep us updated please!
  17. jacob4581's Avatar
    Member Since
    Oct 2009
    Posts
    44
    Nov 16, 2009, 2:37 PM - Re: Han In Carbonite #17

    You beat me to it PFB, I haven't logged in for a bit. The panels were made by Angela and Dung Nguyen and you can inquire about a set from them, they are very reasonably priced for all the stuff you get. Here is their email dnanguyen@yahoo.com again. Hope to have some more progress done after this weekend!
  18. jacob4581's Avatar
    Member Since
    Oct 2009
    Posts
    44
    Nov 23, 2009, 3:00 AM - Re: Han In Carbonite #18

    Got a little bit of work done on the rounded corners this weekend. We did the short corner pieces that will meet the face of the block with Han on it. They didn't meet up exactly, but really close, so we used some sintra scraps to fill the extra space so the corners are as smooth as possible. We used liquid nails to glue the sintra pieces and the .75" corner wood pieces to the frame. Then we pre-drilled 3 holes in each piece of corner wood and nailed them down with finish nails that were countersunk slightly. Once everything is roughed on there and glued and attached I'll go back and use filler, sand, trim, and probably use a black primer on all the sintra sides and the frame around Han before I paint it all silver.


    Click image for larger version. 

Name:	IMG_0241.JPG 
Views:	235 
Size:	613.7 KB 
ID:	38310 Click image for larger version. 

Name:	IMG_0240.JPG 
Views:	218 
Size:	625.9 KB 
ID:	38311
  19. jacob4581's Avatar
    Member Since
    Oct 2009
    Posts
    44
    Dec 1, 2009, 5:49 PM - Re: Han In Carbonite #19

    Over Thanksgiving we got some more done on the HIC. We started by using a belt sander to round off the edges of the quarter round and the sintra pieces.

    Click image for larger version. 

Name:	DSC00080.jpg 
Views:	254 
Size:	533.5 KB 
ID:	38507 Click image for larger version. 

Name:	DSC00081.jpg 
Views:	231 
Size:	442.8 KB 
ID:	38508

    Then we used finish nails to nail down the masonite base and the quarter round on the front on the box. We countersunk the nails again so we can use filler and paint over it to ensure that it's smooth.

    Click image for larger version. 

Name:	DSC00088.jpg 
Views:	251 
Size:	566.6 KB 
ID:	38513 Click image for larger version. 

Name:	DSC00085.jpg 
Views:	212 
Size:	598.3 KB 
ID:	38510

    Click image for larger version. 

Name:	DSC00086.jpg 
Views:	212 
Size:	582.8 KB 
ID:	38511 Click image for larger version. 

Name:	DSC00087.jpg 
Views:	230 
Size:	474.3 KB 
ID:	38512


    Next we mounted the sintra frame for the rubber Han with Liquid Nails. I traced the inside of the frame with a red sharpie so I knew where to glue, rather than glueing on the floppy sintra frame itself.

    Click image for larger version. 

Name:	DSC00082.jpg 
Views:	207 
Size:	508.3 KB 
ID:	38509 Click image for larger version. 

Name:	DSC00089.jpg 
Views:	217 
Size:	523.6 KB 
ID:	38514

    Click image for larger version. 

Name:	DSC00090.jpg 
Views:	253 
Size:	501.7 KB 
ID:	38515


    Finally we mounted Han on the masonite inside the sintra frame with Liquid Nails that we applied a ton of directly onto the rubber. He was a pain to get to stick on there perfect so we put a lot of weight on him to help him out haha. There were a few areas on the edges mainly that we had to periodically go check and re-glue that were coming up a little bit. All in all he stuck on there pretty good though. Almost perfectly even with the sintra frame height in most areas.

    Click image for larger version. 

Name:	DSC00104.jpg 
Views:	389 
Size:	608.5 KB 
ID:	38516 Click image for larger version. 

Name:	DSC00105.jpg 
Views:	387 
Size:	482.8 KB 
ID:	38517

    Click image for larger version. 

Name:	DSC00106.jpg 
Views:	415 
Size:	525.5 KB 
ID:	38518


    Last we measured the length to the head, hands and arms, chest and knee that needed to be filled with expandable foam. We marked the spots and drilled holes, then filled the holes with foam. It will probably take you a few times with the foam to get it completely filled and solid. I will probably get some more done in the next month. Don't want to rush things though. Final steps will be the bondo in the gap areas and sanding and painting.

    Click image for larger version. 

Name:	DSC00107.jpg 
Views:	285 
Size:	578.9 KB 
ID:	38519 Click image for larger version. 

Name:	DSC00108.jpg 
Views:	255 
Size:	720.6 KB 
ID:	38520
  20. Member Since
    Jun 2009
    Posts
    98
    Dec 2, 2009, 4:17 AM - Re: Han In Carbonite #20

    Nice progress! geez thats a nice big prop is'nt it?!
    looking forward to more. Looking great.
    Mike
  21. jawafive's Avatar
    Member Since
    Oct 2002
    Posts
    538
    Dec 2, 2009, 11:02 AM - Re: Han In Carbonite #21

    Great progress! I just need to sand, drill holes, and attach my panels and I'm done. I didn't go 100% accurate, but I am definitely going to have a nice looking han carbo. You have done a great job so far.
  22. jacob4581's Avatar
    Member Since
    Oct 2009
    Posts
    44
    Dec 2, 2009, 2:45 PM - Re: Han In Carbonite #22

    Jawafive, do you have any progress pics of your HIC? Thanks for all the kind words too guys.
  23. ED-VADER's Avatar
    Member Since
    Dec 2009
    Posts
    25
    Dec 9, 2009, 9:34 PM - Re: Han In Carbonite #23

    Awesome work! I like full scale props!!!
  24. Member Since
    Dec 2009
    Posts
    5
    Dec 10, 2009, 8:25 PM - Re: Han In Carbonite #24

    I see reference to "Panels" does this mean that someone out there is pulling the HIC on a sheet of plastic?
  25. Stormrider's Avatar
    Member Since
    Aug 2007
    Posts
    2,271
    Dec 14, 2009, 10:16 AM - Re: Han In Carbonite #25

    The panels are the side panels, the control boxes. There are some very nice ones being made.

    The HICS's are pulled in rubber to make it affordable to ship.

Similar Threads

  1. Replies: 13
    Last Post: Jan 23, 2012, 11:39 AM
  2. Need Help Han In Carbonite
    By AlexBuechel in forum Han Solo in Carbonite
    Replies: 9
    Last Post: May 7, 2010, 12:33 PM
  3. Han in Carbonite
    By Cerillo in forum The Sarlacc Pit
    Replies: 7
    Last Post: Sep 30, 2008, 12:20 PM
  4. My Han in Carbonite
    By chibi fett in forum The Sarlacc Pit
    Replies: 11
    Last Post: Sep 7, 2008, 8:27 PM