This sub-assembly will eventually be glued to the gap in the rear top hull sub-assembly. The top rear engine housing was made from four (4) layers of sandwiched, tongue depressor-sized popsicle sticks cut and shaped using the pattern as guide. The pilot hole was finished using a #953 aluminum oxide grinding stone attachment.Īs illustrated in the detailed steps, each layer consisted of two parts to cover the entire width of the mandible. To make the circular access bays, a pilot hole was drilled using a #125 then a #124 high speed cutter attachment on a moto tool. Another challenge for the three (3) laminated layers was to make the middle layer at a slightly smaller scale to highlight the distinctive top and bottom layer. Lamination was done after the two (2) circular access bays were drilled onto the top and bottom layers. Each mandible consisted of three (3) layers laminated together. The forward mandibles housing the circular maintenance access bays were made from spare tongue depressor sized popsicle sticks. The parts cut-out from the top hull will be used later in the build for the side landing gear mounts. The top hull was laminated and sanded initially as a square and carved into a round shape after cutting-out the gaps for the front concussion missile launcher, cockpit access corridor, port and starboard corridors and rear engine assemble. The bottom hull's shape now resembled Captain America's round shield. Finally, after tracing the pattern for the gun turret mount on the round bottom hull, the entire sub-assembly was sanded using a combination coarse/fine drum sander attachment on a Dremel 3000. The round turret mount was used as a guide to determine the center of the bottom hull sub-assembly. Spare tongue depressor-sized popsicle sticks were carved into a circle for the top gun blaster turret mount. A hobby saw was useful in cutting a rough, round shape for the bottom hull. Lamination of the four (4) layers consisted of gluing each layer perpendicular to the previous layer to reinforce the entire structure. Although both sub-assembles consisted of four (4) layers of various combinations of laminated tongue depressor-sized popsicle sticks and regular sized popsicle sticks, I went with carving a round structure for the bottom hull. I actually used two different approaches for the top and bottom hull. Thank you very very much!Īnd now for the hard part, fabrication of the bottom and top hull sub-assemblies. You can download the file Falcon planv2.pdf from this step.Īgain, my eternal gratitude to the fine folks posting these images for guys like us to use as reference. pdf plans that I actually used for the build. 3D models from provided a general guide as to the main sections of the top and bottom hull sub-assemblies.Īll images and schematics used as reference were from the following sites:Īs with my previous instructables, I've included my Falcom. The main schematic used were from the with images from providing the bottom hull and gear assembly details. Additional searches were done to get details on the Falcon's landing gear, loading ramp and quad gun blasters. Keywords for this build for google and bing image searches are "millennium falcon". The build depleted my entire stock of tongue depressor-sized popsicle sticks that I had to run to a local drug store to replenish the materials to finish the project.Īnd unlike my previous projects with an average of just 6 steps to complete, this build consists of a staggering 10 steps (not counting the intro, materials and tools and images/schematics)! This is my most difficult (and ambitious!) project yet! And I must say that I'm impressed by the end result.Īs with other Star Wars spaceships, images and schematics for the Millenium Falcon there are countless sources from the world wide web. The real challenge for this project was in fabricating the top and bottom hull of the Falcon due to huge size of the ship. The build consisted of three major sub-assemblies - The Middle, Top and Bottom Hull sub-assemblies. The same images were some of the ones used for the front, side and back reference profiles for this project. The project to fabricate the Falcon was planned more than a year ago with Instructable member and a good friend of mine, Blaise_Gauba providing the URLs for the initial 3D model. Manufactured by Corellian Engineering, the light freighter became the most iconic spaceship of the Star Wars saga with Han Solo and Chewbacca, the most famous owners of the ship. Hello everyone, this next project details the steps done to make the fastest hunk of junk in the galaxy - a Millennium Falcon mini popsicle stick model. Oh what a difference a long weekend makes!
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