My Life-sized Han Solo in Carbonite Project - 2nd Attempt

Bought my lumber and started mocking this up. Also, here are some pictures of Vash's side panels. If anyone ever has a chance to get these, don't hesitate, they are super clean and the details are incredible.

Not a whole lot of time to work on this, but its coming along. Finished up the box and rough cut the holes for the panels. I still have the holes to do at the base and the top, then I want to seal this and get working on the front panel.

I also rounded the outside edges and will do the same to the inner edges around the front panel.

I decided to cut out the details on the top and bottom of the case. I don't know where I first saw that, and I am not sure if the movie prop had it, but I like the way it looks. I don't know the exact sizes, so I improvised. You wont really see these anyway when I mount this to the wall.



I used 1/2" MDF for the panel backing. It was cheap and has a nice smooth surface. I also put a few coats of sealer on the wood.



I am using expandable foam to fill in the voids of the HIC cast. I decided to do this first, just because I thought it would be easier than cutting the panel after it was glued down. Also did not want to run the risk of the expanding foam popping the panel off. I'll trim the excess once it fully dries.



Hoping to start priming this sometime next week.

Yesterday I started working on securing the Han front panel to the box. I used a polyurethane adhesive that works well with plastics/vinyl/rubber/etc. I also secured the edges with 1/4 inch wood screws, which helped get a tight bond. I wasn't worried about putting a few holes in the panel since they will all be covered when I pour the carbonite. I checked everything this morning and it's on there pretty solid.







Next I poured the carbonite base. I am using a technique I used on my first HIC build, Elmer's glue with a little hardener/accelerator mixed in. Once this base coat hardens up, I will start pouring several smaller patches to build it up and give it that uneven/frozen look. I figure I will do that 3 times or so.

Looks fantastic! This is one of those builds I've always wanted to do but never gotten around to.

Thanks, I knew I had to jump on this when these front panels were offered up. I think it's the most economical and the easiest way to build one.

Some of the glue is drying fast, so I decided to start with the pooling. Did a couple small spots, will do this at least 3 more times and will try and overlap some of them. Still need to wait for some of the other areas to dry a little more. Once it is all dry and primed it will tie in nicely.

Looks great. Very Nice I'm looking for a finishe front only. Show truck project. needs to be light weight. Any Ideas?

I sold one of these rubber fronts to someone that actually put it on the front hood of their corvette.

The full fronts weight about 20 lbs, the partials like shown here weight about 10-12

I started pouring more today. You can see it dries well, and it even tends to shrink and distort a little adding to the effect. This is a slightly different technique than I used before, but it seems to be working just as I had hoped.













It seems to be layering well. I still have some fine tuning to do. Again, I am hoping this all ties in together once I start priming.

Anyone wanting to try this, let me offer some helpful tips:

- Make sure your box is square and level when you build it, that will help when pouring the glue.
- When you start pouring the glue, it's nice to have compressed air on hand. You can use it to shape the pools and thin them out a little.
- Elmer's glue shrinks when it dries, keep that in mind. You may need to build up certain areas (especially around the edges of the HIC panel) with a few pours.
- Pour in several small coats, rather than one or two large ones.

It's coming together....

I so want to build a HIC desk one day

Now that the two bottom base layers have mostly dried, I was able to start with the texture level. I am using a putty knife to move the glue around, helps give it that random, uneven look. When this dries and shrinks a little, the bottom layers come through just a bit. I'll do one more touch up layer and call it good. I won't know for sure until after I get the first layer of primer on.

The best thing about working with this glue is that it's easy to move and its non-toxic, brings back memories of elementary school, except this time I'm not eating it!

Today I put some primer on to see how everything is tying in. I think the look is great, the technique works; but something is a little off. I need to step back and look at some more reference shots, then re-evaluate how I want to work this.

Thanks for the comments!

After looking at this for a while, and checking some reference photos, I think I found out what was bothering me.

1) The carbonite base seemed a bit thin. Its hard to tell in the photos, but where the red arrow is, I wanted the carbonite to reach that lip. It was too low for my liking.

2) Again, hard to tell in the picture, but the carbonite texture was a bit busy. After looking at some reference photos, it needs to be a little more subtle.

3) The most bothersome to me was that some of the edges of the HIC panel were a bit noticeable. This was caused by the thin layer of glue in some spots. Again, hard to see in the photos, but in person it definitely catches your eye and really bothered me. I highlighted in red some of the edges.

Call me crazy, but I decided to pour another layer on this one. The good thing about the glue; it's cheap and easy to work with. I know had I not done this it would have bothered me. With this extra layer, I am able to build up those edges and hide the panel better and the carbonite reaches closer to the lip.

I'll use the same technique as before for the texture, just on a more subtle level.







Pained me to do it, but had to be done.

Went ahead and put the new layer of detail on. I think I am pretty happy with this. It is still a bit "busier" than the original prop, but it will have to do. I am finding that this part of the build could be done 100 times and you'd still probably want to go back and try it again. It is not as busy and looks more accurate than the last layer. A good technique if anyone wants to try this is after you pour the glue, wait about 5 minutes then go back and lightly drag your putty knife over it. It gives it a nice texture (which is kind of hard to see in the pictures).

I'll let this dry and start on the side panels.

Hey, that glue technique looks great and you've blended the front panel in nicely. Looking great so far and now the fun begins! Building the panels and painting was the most enjoyable part of my build. Looking forward to your next update.

Thanks brother, I will be using some of your techniques for the panels, in fact, I'm using a set of your greeblies that I bought from you more than a year ago.

My biggest dilema right now is the color for the case and front panel. I am changing my mind and wanting to move from the Charcoal Metallic (which I used on my first HIC, see post 1) to a more silver metallic color. I am going to use aluminum for the side panels. But I am not sure what to do about the box. I would like for there to be 3, slightly different colors. The front carbninite panel metallic silver, the side panels aluminum, but I am not sure about the box. I was thinking a Nickel Satin, but that may look very close to the aluminum.

Just not sure. Any suggesstions anyone?

I put a quick layer of primer on so I could start testing some colors. Here is an up-close of the carbonite. I am using a color called Satin Nickel Metallic, I went back and forth between this and my first choice, but I kinda like this. It's a nice silver metallic, but not to strong or shiny.





However, I do need your input for the case color. I have also gone back and forth with that as well. I was going to go with a color called Anodized Bronze, see below.



In the next picture I also tested the Charcoal Metallic (which is what I used on the carbonite for my first project, see post 1), and Medium Gray (which is below the Bronze color).



The panels will be aluminum (you can see where I tested that).

I need some suggestions here, should I paint the entire case silver and use the Metallic Color from post 1 on the carbonite? Should I stick with the Satin Nickel Metallic for the front panel? Should the whole case be that color?

This is making me mental.

Try doing both paints on a scrap peice of wood and take it out into the sun after its dry along with your reference pics and see which color is looking best. You might be able to do a base coat with a darker color and do the highlights in rub-n-buff color thats a bit brighter than the base for the highlights, practiice that on a rock or whatnot and compare with your pix.

Actually, I think I found the combination I am happy with. I decided on Dark Charcoal Gray for the cabinet, the Satin Nickel for the front panel, and aluminum for the control panels. Although not screen accurate, I wanted some color separation from the control panels, the cabinet, and front panel. I have seen many builds where the cabinet is painted the same color as the carbonite. I like to think that the cabinet is a stand alone structure that holds the carbonite, and that the two are completely different substances and look different. At least that's how it is in my crazy head.

Hope to see pics of the color separation you decided on. I went through the same thing with my HIC. I ended up going with Metallic charcoal for the carbonite part and then a darker metallic for the cabinet, but I wasn't really jazzed about how it looked. So when you get it painted, definitely post some pics!!

I will, and that's funny, for my first build I also used the Dark Metallic Charcoal, and I loved it. I was completely sold on it, and if this does not turn out the way I want, then I'll go back to that color. With this build though, I wanted to try a different color for the panel and stick with a non-metallic for the box. We'll see how it goes.

I was able to make some progress today with the panels. I primed them all and started spraying the aluminum. I really like the color, looks sharp against the gray. I drilled the holes for the LEDs and will work on the greeblie covers for the main panel shortly. I also picked up some brushed steel handles from Lowe's for .97 each. I know they are only on the upper right hand panel, but I am going to put them on 4 panels, two on each side.

I also cut out the slot where the green back lit piece will go.

Where the two larger LED holes are, I decided on using two of those metal LED holders to add something extra.





I also worked on the other detail pieces for the first panel. I was originally going to use Bright Metallic Silver, but it ended up looking too close to the aluminum. So I decided on a Krylon color called Brushed Nickel. Not a whole lot of contrast, but just enough and I like the look. I was going to try Rub n Buff, but never got around to getting any.



I also got the first two coats of the cabinet sprayed. I am very pleased with color I picked, Dark Charcoal Grey in Gloss. I went back and forth with colors for this part but this is exactly the color I was looking for. It will contrast nicely with the front panel that will be sprayed Satin Metallic Nickel (I may also combine that color with the one I was originally going to use for the front, Charcoal Metallic). I'm glad I did not go with a metallic color for the cabinet.

You can see the right half is sprayed gray compared to the left half which is still primer.



Here you can see the contrast I was looking for between the cabinet and side panels.

Here is more progress on the main panel.

I went to Lowe's and bought a roll of metal sheeting. I cut pieces to fit in the 3 spaces and drilled holes in the two that will have LEDs. You won't see the metal too much on this first panel because of the greeblies that go over two of the panels (the primed pieces in the first photo below the panel). However, on all the other panels they will be fully exposed. It looks much better in person, and does not blend in as much as it appears in the photos.



I started adding the other details and the two metal LED holders. The Satin Nickel does contrast very nicely with the aluminum, but again, hard to tell by the photos.





Here are two side views that really show off the details. In the last picture I placed the two primed pieces on the panel to give you an idea, they will light up from below.





I did find some Rub N Buff today, and I used it on one of the "T" details (last picture, lower left hand corner). The stuff is pretty cool, never used it before, but it looks too much like the aluminum, so I probably won't be using it.

Less anyone think otherwise, I am borrowing, or will be borrowing, many ideas and techniques from a few other members on this board and others (Bobamaker, D.Nguyen, etc). Much respect to them.

I liked the metallic charcoal for the panel, but like you, I wanted a contrast between the panel and the cabinet. I just couldn't get it right. The non-metallic colors I used were too much of a contrast, but the metallic colors were just too homogenous. So I'm definitely looking forward to seeing what your final color scheme looks like.

Trying to finish up this panel and did a little more work. I originally planned on using an electroluminescent panel, but it was going to cost me about $35. Too expensive and too bright.

I decided to use one solid green LED (thus saving about $34). I was going to use one of my flashing LEDs, but it blinked too fast compared to the screen version and I didn't like it.

To finish the panel I printed a grid pattern on some transparent film (I know, it's not screen accurate). I then cut out a piece of Plexiglas and mounted the grid to the front. On the other side of the glass I added a sheet of frosted velum-like paper.





I then bought one of those plastic capsules you see in the coin machines.



I partially filled it with hot glue, trimmed it, and placed the LED behind it. I did this to help diffuse and spread the light.







To give you an idea of how well it works, here is a shot of the panel with the LED alone directly behind the glass. It is very focused and bright, and the light is way too strong in the middle of the glass.


And here is how it looks after putting the LED behind the glued capsule. It has a softer glow and a more evenly distributed effect.


I think it came out nice.

Sweet--very nice job. I'll be stealing that idea for my panels if you don't mind.

Got a little side tracked with the panels today. After seeing this photo.....



I wanted to try something.

Took a quick trip to Lowe's, spent a couple bucks on some insulation couplers and axle caps, and here is what I came up with. I'll make 8, 4 for the bottom and 4 for the top. I am sure someone will eventually post a picture, but I didn't want to wait, so this will have to do. I am sure it's way off.















I also bought a plastic corrugated "For Sale" sign which I will use for those vent like pieces.

Here's the corrugated plastic "For Sale" sign I bought. I cut it into several pieces and did a test fit with the those vent details. I like it, it will look much better once I add the other pieces and paint. It was a bit difficult to fit these because of the shape of that area.





I also painted the last two detail parts for the main panel and put the switch in. I stole this idea from another member. Drilled out one of the knobs and it slides right over the switch.





I tried to upload an MPG of the working panel, but YouTube said there was an error when I tried, not sure why. So you can see the video here.

hicpanel

or you can go to:

http://www.apbcollectibles.com/hicpanel

Mounted and primed, top and bottom. Spacing is off a little, looks much better in person. Once I mount this to the wall you'll never even see it anyway. So glad I added this though, I love how it turned out.

Looks awesome man. You need to mess it up a bit. Because your getting me slammed with people wanting these thigns now that they see how cool they can be

all kidding aside, your doing a tremendous job.

WOW Stunning! Just need Slave one to put him in, lol!

Fully taped and primed, ready for first coat.



Base coat is Dark Metallic Charcoal. This is what I painted my first HIC panel with, but I think it was a bit too dark. Very nice color though.



Then dusted two coats of Satin Nickel Metallic. Looks a bit too metallic in these pictures, but it's not that overpowering in person.



I am going to do a very light acrylic wash in black, blotted, then a few coats of clear gloss.

Your project continues to impress me. My almost finished HIC has been lonely and thanks you for my renewed interest in him!!

I did my light acrylic wash in black and a coat of clear gloss. I tried to take some close-up photos, they suck, but you get the idea.

I'll put another coat of gloss on then start mounting the panels.

Man, that thing looks amazing! Where can I get the molds from?

Lovin this build bro... I liked the first! but this one... nice...

can you explain your process for acrylic wash?

I hit the high points on mine w/Rub n Buff, but I'd love to add a little more depth to it.

Originally Posted by Mojo-Fett

Lovin this build bro... I liked the first! but this one... nice...

Thanks brother, yeah, I'm lovin this one a bit more myself!

I finally finished the front panel. Put a triple coat of gloss on top and called it done. It was a painstaking process of trying to find the right colors to get the contrast I was looking for, but I have to say I couldn't be happier with how it turned out. I beat myself up over the colors, back and forth, but this is pretty much exactly what I hoped for.







The high gloss gray looks good on the cabinet. Pictures really don't do it justice, other than a few blemishes, it looks terrific in person.

Wow brother.... Outstanding! Really looking forward in seeing it completed.

You continue to excel with this. This is nicer than the two I have built up. It truely shows why the hic han pieces are such a great way to go versus the full top piece.

They are easier to use and more versitileIMHO.

Great job. I personally feel the original was the same color all over, just a different matte. Which can be done by using different undercoats, but i would wager this looks amazing in person.

Originally Posted by Stormrider

You continue to excel with this. This is nicer than the two I have built up. It truely shows why the hic han pieces are such a great way to go versus the full top piece.

They are easier to use and more versitileIMHO.

Great job. I personally feel the original was the same color all over, just a different matte. Which can be done by using different undercoats, but i would wager this looks amazing in person.

Thanks guys! And thanks to you Stormrider, it's hard to take credit for a project like this when guys like you and Vash created the two hardest pieces, the Han front cast and side panels. And I do agree, it was most likely one color. What got me going on this was a pictures I saw some time ago of a guy's home theater. He had a HIC and it was painted similar to this. I had never seen a paint scheme like that before on a HIC and thought it looked great. I know it's not how it looks in the movie, but I like this look better!

Very nice work, but where did you find the parts for the four panels on the side? Did you make them? I've never seen them around on the fourms for sell.

Static

Originally Posted by Staticweb23

Very nice work, but where did you find the parts for the four panels on the side? Did you make them? I've never seen them around on the fourms for sell.

Static

They are around, you need to post a WTB thread. They come up every now and then.

AWESOME...just AWESOME. That is by far the BEST HIC I have ever seen. Amazing job brother...

This thing is just amazing. What was your total build price if you dont mind me asking?

Originally Posted by azheat01

When I start my 3rd, I'll have it down exact!

3rd one! Well when you wanna get rid of your 2nd one... let me know!!!!! ;-)

Originally Posted by Dutch

3rd one! Well when you wanna get rid of your 2nd one... let me know!!!!! ;-)

yeah, if he passes, then let ME know, lol

If you don't mind me asking where did you get the HIC parts?

I make the HIC parts, but the mold is down for the count, im working on a new one.

The project turned out great, congrats!

Im likely going to do one soon for giggles. as I dont like the box shape of the original, but mines going to be an ultra lite version I doubt ill put the love into it you did though.

Thanks for documenting it!

Thanks, and good luck with that, I thought about making a really light version, out of styrene and very lightweight wood. Be sure to post some pics. Hope you get your mold back up, I'll be in the market again for Han pieces down the road!

Colour me, jealous....

AWESOME!

Originally Posted by dsonik1

Colour me, jealous....

Second that!!! love it... want it....
Great work.

Maybe I missed it.. but what did you use for electronics?

It's my dream to get one of these, I'll be following this thread while trying to convince the GF of having one in our place.

Originally Posted by TK-9135

Maybe I missed it.. but what did you use for electronics?

I just used run of the mill LEDs, wired to a 9V battery. If you are not electronic savvy, I would suggest looking for sets on eBay, there are a few sellers who sell them with the resistors attached.

love what you've done.
Dedication + hard work = Great work.

Trying to finish up the details for the panels. Today I added more of the greeblies and made some water slide decals of the alien symbols. I deviated quite a bit from what's screen accurate, I just eyeballed it and went with what I liked.

I still have a bit of fine tuning to do, a few extra decals and greeblies to add.

beautiful! I think that you need 2 of my bases to display your han in carb and your Fett.
http://www.thedentedhelmet.com/showt...-Chamber-Bases

The new mold is done. Need to add keys, and then the shell in the next couple days and ill be up and running again.

Originally Posted by Stormrider

The new mold is done. Need to add keys, and then the shell in the next couple days and ill be up and running again.

Sweet, I'll be in touch. I am going to sell this one, and prepare myself for the next one!

Hi, I have said how nice this is over at the rpf but just wanted to say it again over here. Just joined the TDH to see what you guys get up to. Hope to have a Han hanging on my wall soon. Hope you don't mind me asking for help?

Mark

wow bro that is amazing!!!!!

great work! i want one!!

Just curious what the brand name of the hardener you used is?

I'm just getting ready to start my HIC build. Your thread has
been great!

Sorry brother, I bought it a long time ago at Home Depot or Lowe's. I had it stored in a separate container for over a year after I dropped the original bottle and it broke. It came in a little red plastic bottle. I have been asked a few times and for the life of me I can't remember the name. Every time I go to HD or Lowe's I check and can't find it. If I remember correctly it was used in garage floor epoxy applications, so if they still carry it it'll be in that section or the glue section. If I ever see it again I'll post. You don't really need it, you can pour the glue (if you are using that method) in smaller layers and it will be fine, if you go thick it just takes longer to dry. I used it in the base only, every other coat was done without it.

Good luck.

dude.... your HIC really is cool, would love one... but it would have to go next to the wifes side of the bed.. she aint happy with that!!! so i have to make do with my HIC head in a cabinet!!

Looks great. The glue was a nice idea.

Just now saw this- Wicked Nice!

Your project looks great....Im soooo going to have to make one now....

Always love seeing these things. I wish I had the space to build/display one. Nice work!

beautiful side panels!

Wow the quality of work is amazing.
I have asked the wife if I can have one and she just rolled her eyes at me.
I think that means yes go ahead and build one.

Amazing thread

Craig

Hi Guys! I'm new to this site. I've done a couple of lightsabers that have come out great and recently saw a life mask of Han Solo in Carbonite from the movies. I decided to try and make a life sized HIC and stumbled upon this site. I'm hoping someone can point me in the direction to get a rubber cast of the life sized HIC. Any help would be great.

-"He's no good to me dead."

When I weather my props I use indian ink dilluted with water in a spray bottle instead of paint. then I immediately go back with clean water in a seperate spray bottle. and mist over the ink. I find it gives a natural weathering effect and the watery ink finds all of the minute nooks and crannies nicely. Great work on the build. I am really enjoying this thread.

Thats fantastic!!!
Brilliant job

I'd love to do a HIC, where can you get a Stormrider HIC from???

Thats fantastic!!!
Brilliant job

I'd love to do a HIC, where can you get a Stormrider HIC from???

If you want a HIC cast shoot me a PM. Theres two typs of 'pull' that are used themost for making a lifesize prop.

1 - Full front to the smooth detail. You trim it and make a box to lay it in, seal the edges and your on your way. Getting them to lay flat is tricky sometimes. The rubber I use, and the way I have to make the flat parts thick, makes it not perfectly even (The front of the real IC HIC is not perfectly flat) so theres a lot of work in getting it to lay flat, but the carbonite texture is acurate.

2 - Details pull (A 25% cheaper at least) is the han details, with body,hands,face all as one big piece, and then two toes. You mount them on a board, and make the carbonite texture. Theres a few build tutorials that show a lot of ways to make them like this. This way is easier to get it to lay flat and look nice, but the carbonite texture obviously wotn be screen acurate without a lot of detail work.

The pulls are 300 shipped for a details pull, and 400 for a full front pull. Most the difference in price is based on the amount of rubber I have to use.

My mold has about 10 pulls left on it. Its still making nice pulls, but there is a slight blemish in one of the sides on the SMOOTH section (That typically gets trimmed anyway).

If someone wants one, shoot me a PM.
Thanks,
Mason aka Stormrider

Originally Posted by azheat01

I also have a set of D. Nguyen's panel greeblies, also been holding onto those for about a year.

Hey all.. first post here.. Can anyone tell me where I can get as set of these greeblies?

Thanks,
Dave

Try D. Nguyen on the Yahoo HIC Builders Forum.

awesome build . i just ordered my front pieces from SR so i'll be going all through this thread again and again . u might even get some pm's for advice .

I'm not really sure if D. Nguyen is still making the side panels. I contacted Nguyen and it appears that the side panels have been put on hold for a while. Hopefully they will start making them again. Very nice set from the pictures. If you know of someone else who is making them please let me know. Thanks!

This is very impressive.

Amazing work on this project!!! As soon as my Boba is completed, I will be looking to do something similar. Great job!!

That looks great I wish I could have the skill and time to make something like this.

Sick. Wish I could do this, but dont have the time or money.

amazing where can i get a plaster of han solo i will like to build a project like yours amazing or how can i get in touch any email to get in touch with someone who sell those


thanks

Hey Man, i am new to the site and i think what you guys are doing is awesome, i want to build a HIC for my kids room but i can't find where to get the front and side panels from. while reading about azheat01's adventure with building one, i understand that you may be able to point me in the right direction, could you help me out.

Hey good luck with the build, i am want to build one as well, do you know where i can get the front and side panels?

Brilliant! Just added that in my check list to do under the tab ''Star Wars'' (witch is actually the biggest one)

Just saw a HIC on ebay #738 of 2500 for $1200. Nowhere near as detailed as yours. I think I hear the gears in my brain starting to grind and squeek.

Has anyone ever tried making a life-sized LEGO version of HIC?

I think Lego has made one...think it was lego or a guy, there was one at CV there was a cutout in the head spot for your face to go in