Having completed my 32” Millennium Falcon replica, I decided to wade deeper into studio scale replica space and build what is essentially “my grail build” - a 1:1 replica of the 4 foot filming model. This was built by ILM in 1976, rather hurriedly, as the “Pirate Ship” for the first Star Wars film. I say hurriedly because this is not what the Falcon originally looked like. In 1976, the Falcon model was completed, but then a British TV Show, Space 1999 was released. George Lucas was concerned that their current Falcon model looked too much like the Eagle ships used in the show. So with only a few weeks before FX shooting was to start, a completely new ship was designed from scratch. The cockpit cone and radar dish were two main parts salvaged for the new Falcon.
What remained of the previous model, was refactored into what would become the Rebel Blockade Runner Tantive V.
My build, as described on this page, is intended to be a part-for-part reproduction of the original filming model. At least, where possible and practical. While the original was built on a wooden frame, I’ve designed and 3D printed a frame. There are only hints of what the internal structure looked like, so I just did my own thing with the design. It would have been faster to build the frame from wood, but as I no longer have access to my old shop, 3D printing it will have to do.
Externally, where possible, all the visible “greeblies” are the same model kit parts used to detail the original filming model. Unfortunately, some of the kits used in 1976 were already out of production at the time, so finding them in 2024 can be next to impossible. When that’s the case, resin casts of those parts are used. It would be extremely easy to just design and 3D print those parts, but as ILM didn’t have 3D Printing, and they too cast parts when many of the same thing was needed, I’ve gone with the process of molding and casting the correct parts.
This model is often erroneously referred to as the “5 footer” by model makers as that’s (more or less) it’s overall length. However the ILM crew referred to it as the 4 foot model as that’s the overall diameter of the hull dome. The smaller 32” model became known as the 2 footer.
This build is currently in progress. All images and text will be updated as the build progresses.
Above, the 4 foot Falcon model being detailed by ILM crew. Note the 3 Tamiya 1:35 Panther G tanks.
Right, the first Falcon model compared to the Space 1999 Eagle.
The interior Frame
In 1975, ILM started construction of the ‘new’ Millennium Falcon by building a frame made of basswood or spruce and 4 foot blow molded acrylic domes. Unfortunately I no longer have access to a capable wood shop, and no plastic services company anywhere near me is capable if blow molding acrylic, much less domes with a diameter of 4 feet. So with it being 2023 (when I started the project), 3D printing is a thing. I purchased an Anycubic Kobra 2 Max, which at the time of purchase had the largest print volume of any hobbyist level 3D printer on the market. With the help of publicly available full sized blueprints I created the basic hull in Blender, from there designing an interior frame. The general concept would be to create a lightweight frame akin to a stressed skin structured aircraft wing. The frame would provide minimal strength but maximum shape, the hull domes would provide most of the strength.
As mentioned, blow molded domes were not an option so I purchased a set of vacuformed ABS dome quarters from a fellow Falcon modeller.
Right: The “naked’ ILM filming Falcon showing internal structure and clear acrylic domes.
The frame components were 3D modeled in Blender.
All parts printed in PLA and glued using 2 part epoxy. The tubes are off the shelf aluminum tube from the hardware store.
The port and starboard mandibles were laser cut out of 3mm acrylic. Contrary to many depictions, the mechanical pit holes are not symmetrical.
Mechanical Pits & Greeblies
One of they primary artistic styles of Star Wars is that it’s a “used universe”. Science Fiction files prior to 1977 often presented spaceships and environments being clean and shiny. Some films presented some vessels as used, but Star Wars bright that to a whole new level with the “guts on the outside” style. With that, the ILM crew created a Falcon model with many of the mechanical details very visible.
To accomplish this, ILM model makers used hundreds of plastic model kits. Random parts from Bandai tanks, Tamiya racing cars, and Airfix aircraft, of various scales were combined in ways that gave the illusion of some space magic technology.
While most of the ‘guts on the outside’ were on the outside, there are five ‘mechanical pit’ areas that are inside the hull, yet clearly visible.
The lower starboard mechanical pit. The same area from a 1/72 model kit is shown bottom right. At some point, after filming, the frame from the 1/25 Payhauler (my build in yellow) broke off and was incorrectly reattached sideways. But during filming, it was on its edge as I have it.
The upper forward starboard mechanical pit with the 1:72 Bandai kit version shown along side for reference. Many Bandai kits from the 1970s were used to create the original model in the first place.
Tops and bottoms of port and starboard walkways are complete. To accommodate duplicated parts, some parts were cast instead of buying multiples of $300 kits. It should be noted that the 1970s era vintage koolshade was used rather than the modern version which is very different.
The ILM filming model "JagdPanther" pit alongside an image of my replica. All replica parts are either real kit parts, or casts I've created of the real kit parts. Unfortunately, the real Falcon filming model, being over 40 years old, is now missing parts. My replica has all the parts that have since been lost.
My replica of the main RADAR dish along side the 1:72 scale Bandai kit dish. All parts are either raw kit parts, or I have cast them from my kit parts. I wasn't going to try and source 11 Aurora Sealab kits (At $600 each).
My replica of the main RADAR dish along side the 1:72 scale Bandai kit dish.
My replica of the main RADAR dish along side the 1:72 scale Bandai kit dish.
My replica of the main RADAR dish along side the 1:72 scale Bandai kit dish.
A screen capture from the first Star Wars film for comparison to my replica,
The dish created by ILM in 1976 which was salvaged from the first model of the Millennium Falcon.
The dish created by ILM in 1976 which was salvaged from the first model of the Millennium Falcon.