To properly line up the panels to the sides, a template is made from foam core and cut to the exact shape and size as our panels. A sheet of aluminum from the hardware store is a low-cost rendition of these and once they’re folded, they can easily be fixed to the panel with a screw.ĭecals can be made on an inkjet printer and adhered to the panels. The panels also include these aluminum clips. The “hero” panel (includes LEDs) can have the two panels cut out now as well. The panels can now be touched up with different greys and blacks in order to bring out the various details.

They protrude from the back of the sides by 3 inches so the entire piece “floats’ off the wall. Ensure the wood also has been adhered with wood glue where the wood-to-wood joints meet.Ĭross-members are cut from 2x4s to help support the center section and have 45-degree cuts placed on the back-side. Once trimmed to size, you can simply drill holes through aluminum and bolt it together.

I used 90 degree aluminum sheet stock to secure the sides to the top. When looking at key reference material, there are differing levels of quality being sold, so check the references carefully and find one that looks realistic. The cast of the actual Han Solo was purchased online and comprises the bulk of the project cost. The dimensions are not square as the top is actually more narrow than the bottom. The box for Han Solo begins from a sheet of plywood. We even took the head from a kazoo that had an intricate and functional-looking fan pattern.Ī primer coat of spray paint secures everything and a coat of silver begins their transformation. These parts were secured with 2-part epoxy along with various washers, spacers, and pushpins. The bases of these “Littlest Pet Shop” characters turned out perfect. You can make these out of almost anything – In this case, my kids donated some odds and ends from their toy box. Greeblies – These are the little gizmos that make the panels come to life. Once the bondo has dried (15 minutes), you can remove the part from the RTV mold and being the process again – seven more times to be exact! Once the casting resin hardens (within 5 minutes), you can paint in bondo resin to thicken and stiffen the new part.

This technique is known as “Slush Casting” and is a quick process.īondo Glass is a 2-part fiberglass product which employs bondo resin and small strands of fiberglass. Once the resin is poured evenly in the part, you must quickly move the mold around so the resin fills all of the low voids and coats the sides of the mold. Re: Han Solo in Carbonite - Star Wars Dark Side of the Force Halloween

Life size han solo in carbonite