My Han In Carbonite Project

Fantastic concept - I'd expect nothing less from this and other contributions to the site. Beautiful idea, highly anticipating the finished product!
 
April 11, 2009

I was anxious to get back to work on the project, as I spent yesterday taking my children to see the Easter Bunny at the local Wal Mart, and of course had to purchase tons of candy for the weekend foray.

1) Added a 1x2 support at the head and the foot of the frame to assist in supporting the plywood facia once it is in place. The thought hit me and was kind of a "well duh" moment, as I should have had it included from the get go.

2) Finished up the bottom of the frame, cut out the 2x2x6 supports, and began assembly of the frame. Ended up running out of screws, so I will probably be done for the day unless the wife gets home with the children from her sister's house.


Pics

Top and bottom frame cut out, with new head/foot supports
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The frame about 85% done:
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I still need to put on the last 5 2x2x6 supports, as well as plan out the sliding drawer system I want to include on the HIC where the panels towards the desk chair will be.
 
Further progress:
The last week, I was able to slip in some time between studying for 3 major exams, coaching my sons soccer game on Sunday, and my wonderful wife now requesting me to do some "projects" around he house. (It's amazing how I got THE LOOK....those married know what i'm talking about.....when I purchased my table saw and other odds and ends. Now, all of a sudden it seems acceptable because there's a shelf that needs to be built for this room, a hanging thing to go in that room...blah blah blah that she is requesting.)
LOL...
The sides to the frame/desk were put in place, as well as the surface board where the actual prop pieces will be attached. Again, I can't thank my wife enough for coming up with the idea of making that seperate from the frame itself. This thing gets HEAVY lugging it around. Plus, once it comes to painting, I won't have to tape off anything. I will just be able to remove the center section and spray.
I also spent time designing and making a leaning shelf for my office, so time was split between that and the Han. I wanted to try and get the shelf done ASAP so i can go back to displaying my Star Wars collectibles.
Anyways, here's some progress pics, as well as some with the props on the front facia to get an idea of the likeness:

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Man that is cool!!!!!!! I have wanted to dig in and do one of these for about the last 5 years now, but i just can't seem to tear myself away from Fett upgrades!! LOL Keep postin pics please!!!!!!!!!!! :) Someday, I'll eventually do one, and it is great to have guides to follow!!!! Thanx for sharing!!!
D
 
Well, I had taken a step back from the project because I needed some tools and also after checking the setup, I wasn't happy with how high the desk was going to sit once I would add the glass on top of Han.

So it was back to the drawing board (inside my head that is) determining how to accommodate the person's legs while sitting at the desk without raising the desk, hence the height of the glass top.

Simple task at first, but then you must realize that means actually cutting away part of the frame and the sideboard, making the entire structure less stable.

So I began working in my head how I would take away the least amount of wood to allow clearance for the person, yet still maintain some rigidity. During this past month and a half, I've also been working on my Vader ROTS suit, which allowed me a needed break from Han.

I came back this past week invigorated wanting to continue. I decided on the measurements of my cut, and at the same time came up with a great plan where I'm going to be putting the motherboard, hard drives, cooling fans, and whatnot for the computer once the desk is done and ready to have the hardware mounted into it.

Opposite of the opening where the person will have their legs, I will put a bottom on the desk and inside those two areas the internals of the computer will be housed, with illuminated green and red cooling fans being grafted into the HIC Side Panels.

In the pics, you can also see I started working on the first drawer for the desk. I think it came out pretty well. Keep in mind, this is all coming from my head at this point. I only did the basic sketches for the initial frame. Now it's a matter of working it out in my head, ensuring it's what I want.

Anyways, without further ado:

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Thanks Jedi Paramedic. The pictures don't show it from the angle, but I actually reinforced around the cut out area where the person's legs will go. Now the thing is just as solid as when I had it as one complete piece.

I figured it's better to add on the side of caution for stability purposes. :lol:

That, or have your project come crashing down, including eventually my expensive LCD monitor that will be sitting on top. :cry LOL...

I'm hoping to make more progress on the left-hand drawer this week. Now that I have the first done, the second should be easier.

I have some ideas on how I may want to do the indentations/recessed areas at the head/foot of the cabinet. I was thinking of cutting the holes, and modifying some tupperwear. Bondo the tupperware into the holes, and wallah, recessed area into the cabinet. LOL...

After this is all done, it will FINALLY be time to start bondoing the whole thing and fixing up the little problem areas here and there.

I'm also looking at a possible alternative for Han. There's a gentleman making a copy of the entire front, however it would GREATLY put me over my target of not exceeding $300 of materials for the project.

Ah well, choices...choices.. :D
 
Well, since it was my last day before the next semester started, I wanted to take a bit of time to finish off the other drawer and still spend time with my three kids.

So, here's the pics of what I was able to get done:

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Still not sure if I want to mess with modifying the upper body, having to shape the hands, pour the glue to set the clothes and wrinkles, etc. etc. So I may just bite the bullet and go with the HIC front panel that the gentleman is making for $550:
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Last picture, you can see straight through to where I will be placing the computer hardware:
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Thanks for documenting your process, I'm new to the carbonite building ranks and am getting to the really fun part of my project. I used the hands/torso/face like you did as the general framework. I will post some pictures in a thread when my account has full access abiltiy. It's coming along prety well so far.
 
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