Throwing My 32" Into the Ring - Printable Version

Throwing My 32" Into the Ring - Printable Version

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Throwing My 32" Into the Ring - daverep - 02-24-2013

Okay, I've waited long enough...

So, here's my entry into the 32" Falcon builds. To start off, I'm using joewhite's cutting patterns that he derived from J. Maruska's drawings. Joe I gotta thank you man for all of your help on this! I definitely wouldn't have tackled this if you hadn't emailed me those plans! Big Grin

Even though both Joe's plans and the Maruska drawing were designed for laser cutting parts, I don't have access to anything like that, so I'm cutting everything by hand which is a huge trial & error process. It still works, though. Well, at least so far it has! Tongue

So here are the pics. My apologies there are so many of them right from the start. I've been working on this for a couple of months off and on.

I cut Joe's pattern out and laid it on top of two .06 styrene sheets taped together. Then cut it out.

[Image: DSC_0564.jpg]

Top and bottom cut out.
[Image: 2012-12-21135856.jpg]

Next...to the ribs. These weren't fun especially cutting them by hand but I know they're going to be much more fun than doing the plating.
[Image: 2013-01-26092915.jpg]

I've read on other threads that it's best to sand them down to make sure they're all pretty close to the same size and curvature, but I've noticed that some of those suggestions came after they attached the ribs to the hull, so I decided to tape them all together and then sand them. I figured it'd be much easier doing it that way. Here they are sanded down as best as I could get them.
[Image: DSC_0744.jpg]

So, here comes my first mistake in this process (one of a few so far and probably one of many more), I attached the ribs before I did the center bracing. My logic was that I'd put the ribs in first and then allow the natural curvature to help me in creating the center circle. I figured the circle I drew would be okay.
[Image: DSC_0794.jpg]

Well, in trimming the ribs to match, I trimmed them a bit too far which left me with gaps in some that caused them not to reach the circle bracing. So, I cut shims that helped connect them to the circle, but I also found out that the shims helped to strengthen the whole structure a bit more. I'd still do this again if I was ever crazy enough to try to build a second Falcon. But I'd also create my center ring first.
[Image: DSC_0188.jpg]

So the top and bottom hulls are ribbed and I'm ready to move on.
[Image: DSC_0192.jpg]

In Joe's pattern files, he created some ribbing for the docking tunnels. So, I traced his pattern and cut them out.
[Image: DSC_0188-1.jpg]

The idea behind this is to build the docking tunnels first, before skinning the Falcon and cutting the skin around the docking tunnels. I'm thinking about doing the same thing for the other structures on the hull.

Because I didn't think ahead, I had to remove some of the hull ribbing in order to work with the docking tunnel structure.
[Image: DSC_0191-1.jpg]

I thought it might help if I add a bit more to what Joe did just to make things square and give it just a bit more structure.
[Image: DSC_0199.jpg]

But I realized that I probably had overbuilt the area and went with a simpler approach.
[Image: DSC_0202.jpg]

So this morning I glued the pieces together to see how they fit onto the hull. I think this is going to work, so I'll make three more to fill out the Falcon.
[Image: DSC_0230.jpg]

And here it is sitting in the hull.
[Image: DSC_0238.jpg]

I'm not going to permanently attach it to the hull just yet. I'll put them in and then start working on skinning the hull just to make sure everything fits properly. I'm hoping to have all of those finished by this evening since I've figured out my process of making these.

Thanks for looking!
- Dave

RE: Throwing My 32" Into the Ring - peza - 02-24-2013

eh up dave,loving ya progress mym8,dont worry about the one step forward and one back it happens on this build all the way through.but like ya said it`ll be easier if and thats a BLOODY BIG if!ya ever build another!!
top job!!cheers peza

RE: Throwing My 32" Into the Ring - THX1701 - 02-24-2013

The evolution of of each new build is always intriguing. Seems like with each build, ship builders are taking the best of each build and improving on it. If this keeps up, someday somebody's gonna end up building a real one by accident.

RE: Throwing My 32" Into the Ring - daverep - 02-24-2013

Thanks guys!

The posts mean a lot!
Peza...I'm not sure what's worse, the two steps forwards/three steps back or me second-guessing myself all the time! Tongue

I'm still going to bug you eventually about your landing gear! LOVED that on your build!

THX1701...making one by accident certainly won't come from me! LOL! I have to credit Joe with his cutting plans. But it's fun to see what everyone else has done and try some new ways.

Here are some progress pics from today. Didn't get near as far as I would have wanted with the build. My wife has the same cold I do only worse so I ended up doing stuff with our girls, laundry, cleaning and cooking. But, the top tunnels are finished.

[Image: DSC_0160.jpg]

It's actually starting to look like something now. So, at this point I'm trying to decide whether I should just build the lower tunnels or actually put in the equator walls first, then work on the tunnels. Decisions, decisions...this is where the second-guessing comes in. Big Grin

Thanks again for the compliments...they're very much appreciated! On to figure my next step out...

-Dave

RE: Throwing My 32" Into the Ring - peza - 02-24-2013

eh up buddy.
ya very welcome to ask me anything mym8 on my legs and bays!
and if ya skins are made out of a thinner styrene it may be easier to cut that to shape,but hey there`s always filler! Big Grin

lovin ya progress and ya florence nightingail bit,our house is full o the dreaded lurgy!! Confused

cheers peza

RE: Throwing My 32" Into the Ring - Wombat - 02-24-2013

Off to a great start there with things.

Should be another fine build the way its starting out. Yourself, Joe and peza are doings some fine work.

Thanks for sharing yours.

RE: Throwing My 32" Into the Ring - JAWS - 02-25-2013

You will go nuts building that model.

RE: Throwing My 32" Into the Ring - daverep - 02-25-2013

(02-24-2013, 05:09 PM)Wombat Wrote: Off to a great start there with things.

Should be another fine build the way its starting out. Yourself, Joe and peza are doings some fine work.

Thanks for sharing yours.

Much thanks! Hopefully the end looks as good as the start! LOL! It's been fun figuring things out and trying new things to see if they work. I've been pretty lucky so far, so hopefully my luck holds out.

(02-25-2013, 07:11 AM)JAWS Wrote: You will go nuts building that model.

I think I was already nuts when I decided to do this build, Jase! Tongue

Cutting this stuff by hand is pretty maddening. I'm getting to the point that if I'm off too much, it'll screw things up. I've alreay had to fix things that I have no idea HOW I screwed up. Two in particular...somehow I screwed up the right mandible when I was tracing Joe's pattern and it was off. Stupid thing was that the top AND the bottom were off. So, I sliced both of them off and re-attached them using Joe's pattern and now they're right.

Here's a pic of the joint. It ain't pretty, that's for sure.
[Image: DSC_0191.jpg]

And the mandible holes are off just slightly. Again, I have no clue how I messed that up. So, I'm planning to cut them out and put in a plug with the correct spacing. I'm going to wait until I figure out if I'm going to use pipe or square tubes for the mandible braces.

I'll put Bondo into the seams and figured too, that the plating will hide all of that.

Gotta get my equator strips in first, though.

Thanks again for the comments!!
-Dave

RE: Throwing My 32" Into the Ring - kbilly - 02-25-2013

Another falcon on its way to becoming a masterpiece

RE: Throwing My 32" Into the Ring - daverep - 02-26-2013

(02-25-2013, 01:05 PM)kbilly Wrote: Another falcon on its way to becoming a masterpiece

Man...that's quite a statement to live up to! LOL!

Thanks kbilly...and I appreciate all of the work you and everyone else have done on the parts maps. They're incredible!!

Quick update while I'm at lunch. I got the equator walls in last night. They're only temped in for now...I don't want to permanently attach anything JUST yet. JUST in case! Big Grin

First pic are the braces. The amount may be overkil, but I'd rather be safe than sorry. I haven't made a decision on what to do with the engine...I saw, somewhere...that someone used a strip of lighted material for the engine. I may research that a bit, but may also go the typical route of the LEDs inset back. If I go that route, just not sure how far back to put the stip for the LEDs.
[Image: DSC_0169.jpg]

You can see this in the last photo, but I measured in 1/2" and then spaced for the .06 styrene so that I keep the half-inch space for all of the parts that sit on the lip.

Next is the 1" equator wall temped in with tape.
[Image: DSC_0173.jpg]

And finally the top half sitting on top.
[Image: DSC_0178.jpg]

It's getting there. It finally looks like something now. So, I've taped the two halves together and I'll start working on the bottom docking tunnels and then the walls around the mandibles.

Quick question on the inside mandible walls...they're inset a bit, correct? Anyone have a measurement for the inset?

Thanks for looking and again, all of the comments. (Helps build my confidence a little, LOL!)
-Dave

RE: Throwing My 32" Into the Ring - Stefan Hacker - 02-26-2013

Pretty cool work so far! Looking forward to see more.

RE: Throwing My 32" Into the Ring - daverep - 02-27-2013

(02-26-2013, 10:15 PM)Stefan Hacker Wrote: Pretty cool work so far! Looking forward to see more.

Thanks!! Very appreciated!

Finished the docking tunnels tonight. One more thing completed. Although, not glued together permanently.

[Image: DSC_0190-2.jpg]

Next I think I'm going to start working on the mandible walls and checking the ribs by the tunnels to make sure the hull skin will match up to the tunnels sides. By then my Plastruct order with my 3" tube and 1" square styrene tubing will be in and I can start getting the inner workings going.

Man...still LOT'S to do. Thanks!

-Dave

RE: Throwing My 32" Into the Ring - THX1701 - 02-28-2013

You are putting out the best pictures so far. Some people post great pictures but they post them too small. Great Idea, putting the cat in for scale.

RE: Throwing My 32" Into the Ring - daverep - 01-11-2014

Almost a year later and I'm back on this beast. I have been doing small bits of work here and there, but no major progress within that time to really post anything until now.

A little pic heavy, but at least it will show where I currently am.

Since my last post, I've had to redo one of the front mandibles on the top and bottom halves of the hull so that they matched. That's what I get for cutting this whole thing out by hand. I also needed to adjust ALL of the mandible wells to make them match and to adjust some of them as they were a little off from the filming model. Just a little...

So what I also did is create a poster board template for my outer hull that I'll cut my styrene from. I needed to figure out where to put my seams.

And the entire template on the hull.

And with the docking tunnels added.

I added and subtracted areas of the hull that I screwed up to make a master hull template. I'll then use this to create my cutting template.

And now my most recent work...I've had some "extra time" on my hands since the middle of December due to knee surgery so, I've been able to get a bit more accomplished while I've been off work. Unfortunately, today is the last day for that! LOL!

BTW...the book on the table is NOT mine. It's my 13-year old daughter's. LOL!!!

So, I've gotten my sidewalls temped in and my inner structure temped in. I decided to go with square tubing instead of the round pipe that ILM originally used only for stability's sake. The square tubing has more of a surface area that I can use to attach to the hull halves. I'll eventually cement them in and also attach them using small screws. I'm probably also going to brace the corners where the tubes meet with angle braces to firm those weak joints up. I still need to figure out where I'm going to put the rear braces. I'm also planning to use the sides of the square tubes as my inner mandible walls. I may have to fill in the corners but if all else fails, I'll just attach the model parts to a very thin piece of styrene and just glue that in to place.

I've used 1-1/4" PVC pipe for the mandible well walls and they seem to work really well. They fit almost perfectly in the space between the sidewalls and the square tubing. I did cut out some of the tubing just a bit...just to make myself feel a little better. The fit was actually making me a bit nervous. LOL!

Today and this weekend I'm going to shore up the triangle braces for the sidewalls and also the hull braces. I'm also going to try and permanently attach my docking tunnels. Feels good to be back on this!

Thanks for looking!
- Dave

RE: Throwing My 32" Into the Ring - peza - 01-11-2014

wow man i feel like i`ve missed out on loads of this build,and i`ve just caught up now..top marks mym8!!
cheers peza

RE: Throwing My 32" Into the Ring - JAWS - 01-11-2014

Looking good Dave.

RE: Throwing My 32" Into the Ring - Wombat - 01-11-2014

Wow, that has come along some and more importantly it's looking great! Nice work it's really taking shape now.

RE: Throwing My 32" Into the Ring - daverep - 01-14-2014

Thanks guys! Means a lot coming from you guys. I'm glad I've finally got some time again to work on this. I have my hull pies cut out and anxious to see how they fit. Will share some pics when I get the chance to try them on the top hull.

RE: Throwing My 32" Into the Ring - LastBattlestar - 01-17-2014

Looking really sweet Dave! Seeing those pics makes me want to cut styrene again, it's my favourite building material.

I've used construction glue (Liquid Nails) with great success in strengthening the styrene construction of my Galactica. I'm thinking that it would lock in that square armature of yours VERY well. I've had the stuff inside the G for several years now with zero reaction to the plastic, timber or metal structure. Just a small dab along the seams and internal ribs and braces of your Falcon would make it very strong. Of course, you'd might like to test it on some scrap first for any reaction over time. Just a suggestion. Smile

Mike

RE: Throwing My 32" Into the Ring - dbhs - 01-18-2014

That's interesting. Liquid Nails doesn't eat the stryrene? I would have assumed it would either melt the styrene or go brittle after a while and separate from the plastic parts.

RE: Throwing My 32" Into the Ring - LastBattlestar - 01-18-2014

Nope. I use HIPS, high impact polystyrene, and the liquid nails binds like crazy overnight. Messy when you look inside the model, but incredibly strong and cheap. Best that you test it on your own materials, but I swear by the stuff.

Mike

RE: Throwing My 32" Into the Ring - daverep - 01-24-2014

Mike,
That is an incredible idea! Thank you!!! Smile

I've got some Liquid Nails in my laundry room just sitting. I'm off to test it to make sure it'll work. Didn't even think of that! I was going to just glue the tubes down, but maybe I'll use it like a caulk and if it works, I'll probably also do the sidewalls.

Thanks for the compliments guys! I'll post some more pics this weekend. I have a little more finished, but nothing major. Thought I'd get more time this past week but...

-Dave

RE: Throwing My 32" Into the Ring - daverep - 03-07-2014

I have some more progress pics. These are the most current pics, but I'm a little farther along than these pics. But not by much to be perfectly honest.

It's slow going as usual. So, I finished the templates for the lower hull skin. Again, I used poster board to make the templates and still (as of today) need to cut them out of styrene.

I doubled up on the ribs in some places in order to fit the pieces together. I may eventually add a few tabs to each and shave them down flush to give even more places to glue the seams together.

The trick for me was to match up where the hull skin meets the docking tunnels. I have to say this has been a pain in the ass. I'm STILL fiddling with these areas even now.

So, what I did was get the edges as close as possible to the docking tunnels, then fitted a smaller piece of cardboard to get the edge as snug as possible to the tunnel.

And the finished templates on the bottom of the ship.

So, then I decided to tear apart the work I did on the tunnels themselves. I just wasn't happy the way they were fitting and I also realized that none of the docking tunnels were fitting correctly. So, I took some of the pieces and spent a little time re-engineering.

One of the issues I was having with the tunnels was that they were crooked. So, I decided to use the square tubing to make everything straight and flush. Since I'm not too worried about weight, I thought they'd give a little more support to this area anyway.

And here she is with the revised docking tunnels and the poster board templates on the bottom.

I ended up doing the same thing with the top docking tunnels.

They'll be a little neater when I actually glue them in. I realized that 98% of this model is held together with painter's tape. Tongue

It's been a challenge, for sure. This is my first scratch-build and I'm learning a lot! LOL! The most recent work has been test-fitting the upper hull styrene pieces and realizing that I have some issues with where the hull meets the tunnels, but I've got an idea on how to fix it. So, I'm finishing up with the docking tunnel construction and then I'll start working on finalizing the upper hull so that I can start gluing this stupid thing together finally!

I'll try to get more recent photos up this weekend.

Thanks for looking as always!

-Dave

RE: Throwing My 32" Into the Ring - LastBattlestar - 03-07-2014

Looks good Dave and did I mention how much it makes me want to start cutting styrene again? Smile

Hell of a hull shape to build as your first scratchbuild I must say, but it looks like you have da skillz to get the job done.

Mike

RE: Throwing My 32" Into the Ring - dbhs - 03-08-2014

Dave,
This is looking great. The ribs are giving me flashbacks to the Concept Raider scratch build I did a few years ago. I noted your comment about problems getting the top of the hull to meet the tunnels. On the concept raider was having similar issues (though probably not as complicated). I decided to do 2 layers of of top surface to help solve this. I did the first layer more as a structural top layer glued down tight to the tops of the ribs. I left slight gaps around the hard-to-fit areas. Then I surfaced that with a thinner layer of styrene that was easier to work with and test fit to all of those areas. This was a little more work but a much better result in the long run. Not sure if you can do it the same with the Falcon but maybe an idea.
Doug

RE: Throwing My 32" Into the Ring - daverep - 03-09-2014

(03-07-2014, 03:50 PM)LastBattlestar Wrote: Looks good Dave and did I mention how much it makes me want to start cutting styrene again?

Hell of a hull shape to build as your first scratchbuild I must say, but it looks like you have da skillz to get the job done.

Mike

Mike- Thanks, man! Cutting this whole thing by hand certainly has been an adventure and certainly has made the build...interesting. LOL! I think if I had all of this laser cut, it would have made it a little simpler. LOL!!

BTW, I did a test of the Liquid Nails idea and it kinda worked. It didn't melt the styrene but it peels really easily if you rub it. I found a small tube of it at Home Depot. It definitely holds for sure, so I'll probably try go ahead and put a seam of Liquid Nails along the corners of the square tubing just as an added bonus. LOL!

(03-08-2014, 07:21 AM)dbhs Wrote: Dave,
This is looking great. The ribs are giving me flashbacks to the Concept Raider scratch build I did a few years ago. I noted your comment about problems getting the top of the hull to meet the tunnels. On the concept raider was having similar issues (though probably not as complicated). I decided to do 2 layers of of top surface to help solve this. I did the first layer more as a structural top layer glued down tight to the tops of the ribs. I left slight gaps around the hard-to-fit areas. Then I surfaced that with a thinner layer of styrene that was easier to work with and test fit to all of those areas. This was a little more work but a much better result in the long run. Not sure if you can do it the same with the Falcon but maybe an idea.
Doug

Doug- thanks for the advice. I'll have to see if I can incorporate your idea. I might just end up piecing a smaller sliver of styrene if needed and just covering the seam with Bondo. I think the hull plating should cover most of that...similar to what I had to do with my mandible wells. But I'm definitely going to keep your idea in mind! Thanks!!! Big Grin

BTW...COOL PICS!!!!

Thanks guys!
-Dave

RE: Throwing My 32" Into the Ring - peza - 03-09-2014

eh up buddy,wow mym8 your build is really movin on,love the progress keep up the great work!!cheers peza

RE: Throwing My 32" Into the Ring - daverep - 03-11-2014

(03-09-2014, 05:08 AM)peza Wrote: eh up buddy,wow mym8 your build is really movin on,love the progress keep up the great work!!cheers peza

Thanks Peza! It's getting there, but tonight I decided to rip out some of the ribs near the upper docking tunnels. I glued (yes, actually GLUED instead of painters tape Tongue

) the upper docking tunnel structures together.

I'm much happier with the results than what I did before, but realized that the starboard tunnel didn't fit right. So, I tore out some ribs. I'll post some pics tomorrow.

-Dave

RE: Throwing My 32" Into the Ring - peza - 03-12-2014

eh up dave!
here are some images of how it`s mean`t to be,but i`ve not addressed that bit yet mym8.
the first image is of the fine molds version which is as i`m told as close to the 32" version.
[attachment=15668]

the second image is from tim ketzer`s version which is where i`ve got all my printout`s to work from.if you need any images just check out his page,which is his name followed by .com. Heart

[attachment=15669]
and finally i`ve got the blue print`s and it say`s the same.
[attachment=15670]
hope that`s the info ya after dude,if not let us know and i`ll do my best to help!...
on your build m8 dont worry about the re-buildin stuff it`s part and parcel in the world of scratch,as ya change the smallest thing it just build`s into the butterfly effect!!cheers peza

RE: Throwing My 32" Into the Ring - daverep - 03-14-2014

(03-12-2014, 06:33 AM)peza Wrote: eh up dave!
here are some images of how it`s mean`t to be,but i`ve not addressed that bit yet mym8.
the first image is of the fine molds version which is as i`m told as close to the 32" version.

the second image is from tim ketzer`s version which is where i`ve got all my printout`s to work from.if you need any images just check out his page,which is his name followed by .com.

and finally i`ve got the blue print`s and it say`s the same.

hope that`s the info ya after dude,if not let us know and i`ll do my best to help!...
on your build m8 dont worry about the re-buildin stuff it`s part and parcel in the world of scratch,as ya change the smallest thing it just build`s into the butterfly effect!!cheers peza

Thanks, Peza for the images! I'm trying to figure out exactly HOW the PVC for the cockpit tube sits in the hull. Looks like it sits in the bottom half of the hull. But I'm getting ahead of myself as usual. Tongue

But you're right, the butterfly effect has certainly been plaguing me on this build! LOL!!!

So, a quick update while I'm on my lunch break at work...

Work on my docking tunnels redo. I think the pics show what I'm doing.

Now, this is probably all overkill, but at the very least maybe it'll give me some long-term support?

So last night I finished the lower docking tunnels as well and fitted all four of them onto the hull. Pretty pleased. I think I might be on the right track now. I did have to remove some more ribbing to make one of the lower pieces fit.

In the next couple of days, I'm going to work on getting the hull slices trimmed to fit correctly against the tunnels and then see what I can do with the cockpit tube.

Once I get all of the major hull pieces fitted to where I'm comfortable, then you'll start to see the blue painters tape disappear as I glue them together. I also have to think about the hull wells. Need to figure out how deep to make them.

Back to work...thanks for looking!
-Dave

RE: Throwing My 32" Into the Ring - peza - 03-14-2014

eh up buddy,sorry mym8 i must of miss understood ya!
the bottom of the tunnel is at the same height as the bottom of the side skirt,so then the armour plate is the only thing that need`s cuttin to shape.hope this helps dude,if not please let us know and i`ll send ya an image of mine!lol...i`ll show ya mind if your show me yours!!!ha.....cheers peza

RE: Throwing My 32" Into the Ring - daverep - 03-14-2014

(03-14-2014, 06:24 AM)peza Wrote: eh up buddy,sorry mym8 i must of miss understood ya!
the bottom of the tunnel is at the same height as the bottom of the side skirt,so then the armour plate is the only thing that need`s cuttin to shape.hope this helps dude,if not please let us know and i`ll send ya an image of mine!lol...i`ll show ya mind if your show me yours!!!ha.....cheers peza

LOL! Not a problem and you just confirmed what I was thinking.

Much appreciated!! I'll probably snap a pic myself and post it to see if I'm correct. Gotta' do some removing of styrene first, though! Story of my life with this bird... Tongue

-Dave