Just started this build a couple of weeks ago and now have the torso done. I always wanted one and so do the guys in my squad, so I will be making molds and poping a few of these out form them. I had no luck finding a Han cast so decided to make my own. You can see my progress here.
Scratch building the control panels
These will be cast with the back side open so you can add the aluminum panel behind it and electronics. They will be cast from high temp urethane so lighting will not warp the panel as they get hot.
Made this copy on my printer. Its about 21 sheets. for the 1:1 scale copy of a good picture of a HIC block positioned on the correct size board. This is the end prduct I am shoting for.
Torso section of photo cut out for body reference
Foam cut out, glued on and ready for shaping
Contoured with a rasp and course sandpaper finished and ready for the clothes
View of wrinkle detail
Found some old work pants and a shirt and glued them onto the foam shape
These clothes really came close to original
I used fiberglass resin to coat the form
Three gel coats and the last sanding
Silver paint sprayed to check progress easier.
Side angle, this came out better than expected!
Torso with photo template laid around it
Front view. Ready for head and hands to be placed on.