Redditor dinoignacio’s daughter wanted a Millennium Falcon for Halloween, so he made her one. She already had a Rey costume from The Force Awakens, and the Falcon goes perfectly with that. Dino designed the ship so his daughter could wear it over her shoulders. He used easy-to-find supplies like foam core board, paper cups, twist-off bottle caps, spray paint, and a few other odds and ends. He used the foam core to make the structure of the Millennium Falcon. He said:
I made the outer circular part as wide as the widest possible circle I could cut out of the sheet. The board was 20×30″ so the main circle is a 20×20″ circle.
I added the prong shaped front of the ship and the slightly angled cuts on the side of the circle.
I also cut a circle from the center of the base shape. The diameter of this circle is 11″.
I made 2 of these base shape pieces by cutting one out and tracing it on to the other sheet.
I then cut five 30×3″ strips of foam core.
I took 3 of these strips and lightly scored them on one side vertically at 1″ intervals. This allowed me to snap them along the score lines and bend the foam core into a curve.
Using a glue gun and starting with the inner circle first; I glued on the curved foam core along the edges of the base model. I used the scored strips along the curved parts and the flat strips along the straight areas.
With the help of his daughter, Dino glued small pieces of foam core, paper cups, and straws to replicate all the details on the exterior of the Falcon. You can see a picture of this stage just below.
Learn more about the build in this gallery at Imgur.