Han In Carbonite: In the rubber

Stormrider

Well-Known Hunter
A little over a year ago, I purchased the HIC from FP. I didnt know if he would want it back before he moved from the area, so it sat in my basement waiting. Seeing as it seems FP is so busy he cant walk, and didnt express any interest in taking ol' han with him back to the land of rain and mountains, he became what appeared to be a permanent fixture.

Recently, a local mold company and I were discussing how to best make a mold of it. Well it became a challenge for both parties concerned, and low and behold, hes now sitting under his first layer of silicone.

We are trying to determine if we want to do full depth replications, or only 1 inch deep. At the minimum, I intend to make myself a copy, have the electronics boxes all the way around cut from aluminum, and have it cold cast in bronze, instead of the gray/silver.

I know there has been a few attempts to put a run together on these. Which as far as I can tell, have all failed. This one wont, even if its just a run of 1:)

I think that for a finished piece, were looking at around 300 to 500 _shipped_, and if you want to pick it up, no shipping obviously. This is for one in one of a few different meterials. On the list so far are:

1. Ultralite (think fishing lure material) resin.
2. Skin coat flex (resin, but with flex)
3. Flexible 80 resin (with foam backing)
4. Flexible 80 with no backing (can be rolled up for shipping.

Ill be doing a true cold cast bronze for myself, that will need to be buffed to shine (like the jango helmets).

The 1 inch deep cast is for my home office, to go under the class for my desk. I saw a pic of one around here somewhere that did that, so I figured it would be a good way to go.

Im estimating the mold to cost me $500-$800

Im estimating each piece will be 150 in materials, and im estimating shipping a 1 inch, rolled, or slized (on a ban saw to be re-put together at the end location) $50 and a full size 1 inch deep shipped $100-150

Id prefer to do these in a medium that doesnt break easily for the ones being shipped.

The local modl shop (which is a national mold shop) says they can get me great deals on shipping. We will see how that turns out.

The mold is going to take some serious time to build up. Expect pictures late next week of progress.

Let me know if your interested (I understand pending pics) but lets assume for the fun of it, that it turns out as clean as the rest of my projects and the price stays SHIPPED at 400-450 EDIT: Price ended up being 375 for black and 400 for silver shipped US. Roughly 40 more to europe, 80 to australia
 
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Im not sure how the whole would ship over seas, but I think a rubber rolled, or a sliced in 3's wouldnt be difficult at all:)

Probably ship for less than 100 bucks.
 
Im working on getting cnc copies of the electronics parts on the sides, to make a nice clean mold.

I could supply an electronic piece to someone with a nice vac machine, and they could probably pull those alot cheater than me casting them.

Ideally though, the front where theres texture, would be cast and then cut down, to be inset into a box you would build yourself.

I put one together out of orange styrofoam from home depot, and then paitned it grey, with a face cast, and a cheaply made rest of body, and they carried it walking 10 miles no problem in a parade.
 
WOW !! HIR ?? That is an awesome idea Mike !!

I'm glad to see this finally getting off the ground. I couldn't be an Indian giver (seller) :lol:

And yes, I'm walking kind of funny these days :cry

I think you've got what it takes to pull this off without a doubt. I for one, would be seriously interested in one made of rubber actually !!

You sure you've got the mold materials figured for that right though ?? It's probably based on how thick (how many layers your pouring before backing of course). The last person I think did this was upward of $1200. But I think he nearly poured a "slab" mold :wacko :lol:

Watching with anticipation (y)



FP
 
Yah brother, the local place now sells me all my mold materials at cost. Rubbers and resins:) Theya re going to do the build up each day for me. Ill have to get like a 5 gallon bucket of hs3, which is like 400 bucks. and some foam. Im guessing 750 ish for the materials for the mold.

I think secretly the owner wants one for himself, thats why they want to help make it:)

Yah the rubber will be cool. Im thinkign 10 lb soft foam backing on rubber. That way it will hold its shape unless pressed _hard_. Besides we all know the real problem with shipping these is they break. But in hard rubber? No such problems:)


The rubber is the same rubber the knees are in. So it should stay firm.

Hopefully no one interprets my comments above about you not taking him, as negative. Trust me, I wanted to keep him, but its like being a foster parent. Dont get too attached to the kids, cuz they might get yanked out from under ya.

There are fewer and fewer of these around these days. And im trying to do this at a dollar amount that people can afford. Because until youve had one you have no idea how cool it is:)

Ill get some shots as we move forward. I have a mold I made of the face down stairs, im going to play around with some different casting materials while I wait, to see what works best. Im going to start with a bronze cold cast (powder not filler)
 
Oh HELL yeah I'm interested! Han in rubber, rolled up would be flat out (har har) awesome. Then not only is it easy to ship, but easy as hell to store it until the whole rest of the box can be completed.
I might have missed it, but what color would it be cast in for the rolled up rubber?

Subscribing to this thread so I can be right on top of this progress. lol
This is great timing, I have to say! :)
 
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I seriously doubt i will have the cash to get one, but dang...I sure would like to!!!!!! I guess you could say I'm possibly interested!! Lol. That is however, a very modest price range!!! Better start saving my pennies!!! Look forward to pics!!!
 
In the hard rubber, it would be in black. Or a dark gray. The real piece is gray, not a bronze/metallic like in the movie. Its either made incorrect, or its the red lighting on bespin and jabbas palace that give it the red tint.

For the rubber casts, id probably back fill the hands and face and toes with flexi foam, so they keep their shape.

Ill make a hard rubber face cast this week, and post some pics to get a handle for it:)
 
Always wanted to have that trophy and considering I live in Ann Arbor pick up would seem prime. Just gotta raise the scratch here to afford it.
 
I could probably pour one tonight with some spare materials I have laying around, just to get a feel. Depending on when vball gets over.
 
In the hard rubber, it would be in black. Or a dark gray. The real piece is gray, not a bronze/metallic like in the movie. Its either made incorrect, or its the red lighting on bespin and jabbas palace that give it the red tint.

For the rubber casts, id probably back fill the hands and face and toes with flexi foam, so they keep their shape.

Ill make a hard rubber face cast this week, and post some pics to get a handle for it:)

Awesome! Sounds great!
And yeah you do really see the color in Bespin of the really nice silverish gray over the color in Jabba's Palace.
And the backfilling sounds like a great idea too. I was wondering if the details like that would be hollow or filled in. So essentially, would the back be flat solid while the front has all the details in the rubber?

I guess I should just shush up and wait for pics than asking all these questions. LOL
 
Interested....Our local garrison table does'nt seem to have
a lot of static props. This would be a great way to help out
and provide more for ppl to look at. I love your work SR!
 
Ok first pull of my test mold. In rubber. I pulled a hard plastic and a 80 durometer rubber. One coat. Its a little thin, but backed with a 10 lb foam, would be perfect.

But of course, you tell me:) The pictures dont do it justice. Its cast in bronze cold cast rubber. Im thinking that outside of the amount of materials for each one, and the time consuming nature of sloshing/building it up, it shouldnt be all that difficult a project.

Boy, am I excited;) The pictures are the same piece btw. The first is a much better representation of the color, but taken with my iphone, so no flash or adjustments.


rubberhan.gif
 
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