The Han Solo in Carbonite Project

There is never enough time in the day to get things done.  So when it comes to side projects to dress up the studio it’s almost impossible to find any time at all. Our Current project is to replicate the Han Solo in Carbonite prop from “The Empire Strikes Back”. This might take a long time but it will be a great piece to hang on the wall.

So the first thing I need to do is build the box.  I’ve scaled up my drawing in Enroute and have created the “control panel” holes. I’m going to cut the box out of 3/4″ MDF then create my insert out of 2″ Insulation Styrofoam.  The control panels will be made up of KDF and acrylic.            130 131   Once my wood panels are cut its time to cutout the foam insert that will hold Han up – this will eventually be coated to look like carbonite.


015 The face plate is fitted and matches perfectly. Now I’ll screw it all together, add a cleat to the back and move on to Han.




I’m going to carve his body our of 10lb Precision Board HDU. Once the bulk of it is done I can sculpt details on top. On this part I’ve got my helper Owen running the machine for me. 080

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The carving is done – Next step is assembly.  stay tuned….


Published with permission from KDF Custom Graphics. Source.