Want to turn a tricycle into the fastest hunk of junk in the galaxy? Instructables user JuanW did just that. He turned a tricycle into a Millennium Falcon for his nephew and also crafted a little Han Solo costume and a Chewbacca teddy bear. He decided to build the spaceship from rubber foam and designed the layout based on the tricycle. He compared blueprints of the Falcon he found online with photos of the tricycle until he was happy with the scale. He says:
Once I had the correct measures for my Falcon, I divided the design in pieces. At the place where I ordered the rubber foam, there were certain limitation with what they could do so I designed my pieces having this is mind. Basically you can order a profile cut of a piece of any thickness you want but the can’t make cuts that are not perpendicular to the surface of the piece. So things like the cockpit or the docking bays that are truncated cones can’t be ordered so in this cases I ordered cylinders and then I would have to form the cones by hand.
I needed to provide them with cutting templates for the pieces so I composed all of them in a 1.2 x 2.2 m canvas and printed it in banner fabric in a plotter. Banner fabric is not easy to deform, it is vinyl coated and it does not tear apart.
I cut all the templates, each one with an indication of the thickness of the piece (I also grouped them by colours) and took them to the rubber foam factory.
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