Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

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Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby royjess » Fri Mar 17, 2017 8:52 pm

The Falcon model now finished, I'm now going to turn my focus to building a display case with diorama to fit her in. I've already drawn up some plans.

My diary build for this will be coming soon.

My diary builds can be found here

Issues 1 to 25 viewtopic.php?f=168&t=6141
Issue 26 to 50 viewtopic.php?f=168&t=6664
Issue 51 to 75 viewtopic.php?f=168&t=7117
Issue 76 to 100 viewtopic.php?f=168&t=7451
Completed Builds Hachette - The Black Pearl
Completed Builds DeAgostini - Build the Millennium Falcon

Always thinking outside the box....!
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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby royjess » Fri Apr 21, 2017 7:16 pm

I've been working very hard over the last couple of weeks on the next stage of this project.

Today I've just completed the next stage and I've just tested it with my fingers cross that it works.

To find out what I've been up to and to see me testing it, check out this short video

https://youtu.be/eLytstbZnTs

Diary will follow soon

To be continued...
Completed Builds Hachette - The Black Pearl
Completed Builds DeAgostini - Build the Millennium Falcon

Always thinking outside the box....!
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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby number1 » Fri Apr 21, 2017 8:49 pm

Excellent job Roy, all the extras you've put in were certainly worth every penny. K from me :clap: :clap: :clap:
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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby steve131 » Fri Apr 21, 2017 10:51 pm

Great work Roy ,number one Daughter and I built a paper Falcon today.
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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby royjess » Sun Apr 23, 2017 5:37 pm

Thanks for your kind comments

steve131 wrote:Great work Roy ,number one Daughter and I built a paper Falcon today.


Sounds cool. Do you have a diary or photo?
Completed Builds Hachette - The Black Pearl
Completed Builds DeAgostini - Build the Millennium Falcon

Always thinking outside the box....!
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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby royjess » Mon Apr 24, 2017 4:02 pm

If you haven't seen the youtube video in my previous post above, please go and watch it in full before you continue to read

Here is the link to the video again https://www.youtube.com/watch?v=eLytstbZnTs

Disclaimer. You follow and copy my idea of lifting your Falcon entirely at your own risk and I will not accept any responsibility for any injury, death or damage to your Falcon as the result of doing so. The Falcon is very heavy at approx 24lbs /10KG. It is down to you to ensure that the lifting mechanism is made from strong material, sturdy and will not topple as well as for you to maintain and do regular checks for wear and tear, especially where the mechanism pivots.

I got the idea of having the Falcon take off a few years ago, when Jess and I visited Legoland Windsor and saw the lego Falcon lifted off. I just couldn't get Jess away as she kept saying that she wanted to watch it one more time, I needn't to say that one more time turned into many one more times.

We did thought of purchasing a Lego Falcon to build one, but when we heard about the DeAgostini test run build the Millennium Falcon, then that is what we were going to do.

As I continued to build the Falcon, it was apparent that the Falcon was not only going to be large, but also very heavy. So will it be practical for me to make it take off using very basic metal work skills and limited space in the home as well as keeping everything light in weight.

I also have no welding experience. I initially thought of using a see saw approach with a counter weight, but this will need to take up double the room. To keep the Falcon sitting in the horizontal position, the Falcon would need to have two lifting arms running in parallel.

So after over two years in the making, a day in designing and two weeks building the lifting mechanism, this is a diary to what I came up with.

I decided on 7 x 20mm x 40mm x 18" Stainless steel tubular metal, which I ordered from ebay and had pre-cut to size. I did modify the lifting mechanism so you might want to have 3 of the metal tubular metal cut at a longer length for the base to help with the balance and make the lifting mechanism more stable.

I also purchased some stainless steel flat bar, 40mm x 3mm and also some 50mm x 3mm, yet to be cut to size by me.

I used stainless steel as a choice of metal for it strength as well as rust resistance

Image

I decided that instead of welding the metal together, that I was going to use nuts and bolts. So I needed to drill some holes. Most of the holes were 8mm to take M8 bolts, some were 6mm and smaller to fix on the rubber door stops and the wall mounting plate that came with the final issue for the subscribers.

To drill the holes, I initially tried to use my hand drill in a drill stand, but this was useless. I invested in a proper pillar drill costing just under £50 off ebay. Drilling at low speed using Cobalt drill bits and oil with not too much pressure on the drill bit made it easy work.

Image

To be continued....
Completed Builds Hachette - The Black Pearl
Completed Builds DeAgostini - Build the Millennium Falcon

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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby steve131 » Mon Apr 24, 2017 4:13 pm

royjess wrote:Thanks for your kind comments

steve131 wrote:Great work Roy ,number one Daughter and I built a paper Falcon today.


Sounds cool. Do you have a diary or photo?

Sadly we not good with tech no photos ,built C3PO yesterday.
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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby royjess » Mon Apr 24, 2017 4:29 pm

You probably spotted in my previous post in the photo that I cut off a small section (40mm) off two of the tubular metal lengths. At the time of ordering the metal I didn't know the height of the actuator, the two 40mm pieces also were kept to act as spacers for the support bars

The metal was de-burred, abraded and cleaned with white spirit.

Everything was given a couple coats of black smooth finished Hammerite spray paint.

Image

Two of the lengths had rubber door stops fitted to act as rubber feet

Image

End caps (20mm x 40mm) were also fitted which can also be found on ebay. These are fitted to all the metal tubular parts.

Started to take shape

Image

Image

The actuator only moves 2"

Image

Remember those 40mm bits that I trimmed off?

Image

To be continued...
Completed Builds Hachette - The Black Pearl
Completed Builds DeAgostini - Build the Millennium Falcon

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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby royjess » Mon Apr 24, 2017 4:30 pm

steve131 wrote:
royjess wrote:Thanks for your kind comments

steve131 wrote:Great work Roy ,number one Daughter and I built a paper Falcon today.


Sounds cool. Do you have a diary or photo?

Sadly we not good with tech no photos ,built C3PO yesterday.


That's a shame, I would love to have seen pics of both of your droids
Completed Builds Hachette - The Black Pearl
Completed Builds DeAgostini - Build the Millennium Falcon

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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby royjess » Mon Apr 24, 2017 4:59 pm

Just in-case you haven't gathered, that the mounting plate fitted to the top of the lifting gear is what was supplied by DeAgostini, it's part of the wall mount that came free to us subscribers.

The actuator is supposed to lift up to 165lbs in weight, but with the actuator position towards the opposite end of the lifting arm, which moves the centre of balance, which will increase the lifting weight, will the lift actually lift the Falcon? After 2 weeks of building the lifting mechanism, will it work? I was very apprehensive when testing it. And yes it worked as you can see in the video posted above which was filmed shortly after I very first tested it.

The only disappointment that I had was how much of the lifting arm was situated below the Falcon. 8" below which meant that the illusion of flying was destroyed. Unless you view the take off from above as in my previous video.

So I decided to modify this but without compromising the strength and balance of the lifting mechanism. I decided to add a piece of metal from the wall mount and this improved the illusion of the Falcon flying

Image

Penny Washers were used along with the bolts supplied to secure the Falcon to the mounting plate.

Image

The electrical wires were routed though the end of the lifting arm by drilling a holes in the end caps. The wires were covered with heat-shrink but I didn't shrink them just in-case I need to service the wires at a later date.

Image

Image

Image

And the wires coming out of the back of the lifting arm, I need to cover these with heat-shrink and then re-attach these to the controllers/battery packs

Image

To be continued.....
Completed Builds Hachette - The Black Pearl
Completed Builds DeAgostini - Build the Millennium Falcon

Always thinking outside the box....!
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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby royjess » Mon Apr 24, 2017 7:47 pm

Here is a video showing the modified lifting gear, it's surprising how much difference it makes just by adding that extra piece of metal makes.

https://youtu.be/do4N3sSdBIc
Completed Builds Hachette - The Black Pearl
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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby royjess » Mon Apr 24, 2017 8:11 pm

I would also like to mention that I used Nyloc nuts,

https://en.wikipedia.org/wiki/Nyloc_nut
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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby royjess » Tue Apr 25, 2017 9:26 pm

I covered up the wires that came out of the rear of the lifting arm with some heat-shrink, just like as I did with the wires coming out of the Falcon into the front of the lifting arm and again I did not shrink the heat-shrink just in-case I needed to replace any the wires at a later date.

The wires was re-connected to the battery boxes using block connectors.

To control the lifting gear, I decided to fit a Gimson Robotics radio control box which came with a key-fob controller. The photo below also shows the key-fob that was supplied by DeAgostini

I'm also going to purchase another Gimson radio control box to operate my satellite dish by remote control.

Image

To be continued....
Completed Builds Hachette - The Black Pearl
Completed Builds DeAgostini - Build the Millennium Falcon

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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby casper » Wed Apr 26, 2017 7:43 pm

looks excellent Roy :clap: :clap:
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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby Mark » Fri Apr 28, 2017 12:09 pm

Very impressive Roy !
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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby royjess » Fri Apr 28, 2017 4:20 pm

Thanks for your kind words.
Completed Builds Hachette - The Black Pearl
Completed Builds DeAgostini - Build the Millennium Falcon

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Re: Roy's Build The Millennium Falcon-Part 5 (Display Diorama)

Postby casper » Fri Apr 28, 2017 10:25 pm

Love the video :clap: :clap: works really well and looks awesome
great idea roy
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