I just wanted to share my build with everyone. When I first found this site I was very excited to see that I could build my very own HIC at a reasonable cost.
I spent many hours looking at all the posts trying to gather as much information as I could, so thank you to all those who've helped with any questions I had.
It took a few weeks to track down all the parts I knew I would need to start this build, but once the pieces started showing up I couldn't wait to start.
I started with a HIC box kit from Zenix, which arrived very quickly. The online instructions good and easy to understand. I had to make my own corner pieces to attach the sides and top to.
But was able to determine all the angles needed. One peice of advice when the instructions say 2x3, their is a reason! A 2x4 is too wide and will overlap into the control panel holes, so I had to rip mine down to fit.
The full body cast is from Stormrider, which looks amazing. This was THE peice i was waiting for before I started by build, so once it arrive I couldn't wait to get started.
So I sectioned off a part of my basement, which would make Dexter proud, (knowing I will do all the spray painting here later on) and started constructions...
First laid out the HIC kit
I first glued the puzzle pieces together.
Once the glue dried I put the shell of the box together
Then added the frame to the front of the box
I added some wood filler to the sides to fill in any gaps between the "puzzle" piece connection, thinking it would need some added strength when handling it later when putting the box together.
Added the backing, used 2 4x4 sheets of 1/4" MDF board to anchor Han to. I screwed it through the front of the frame. I used a 1x4 on the seem just to strengthen the seam.
Completed box, you can see the pieces of MDF laying next to the box which i will use to attach the control boxes to later. I've been going back and forth on if I wanted to angle the sides or not.
Who couldn't resist to see how Han would look in place?!?!?!
As you can see some trimming is required to make the cast fit inside the frame.
I then choose to round over the edges using a 3/4" router bit.
On to filling those all those screw holes. I ending up using drywall compound since I had a lot left over from a previous project and knew it would be easy to sand.
It takes a little longer to dry completely vs bondo or wood filler, but was willing to deal with the added drying time. Only needed two coats to get all the holes