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