How durable will the blocks be? I cut mine from wood and sanded each one. I had the larger center piece and the smaller pieces on the inside and outside. Took forever!
Yeah, we simplified it by going with only one row of blocks, instead of three. The PVA glue and coat of primer hardens the surface a bit, but they're still just styrofoam. We don't expect a lot of wear on the blocks (Vader will be guarding the door most of the time).
Finished the curved corners and set the front panel on:
Bought some hose to use as the edging for the door:
All I can say is WOW! You have done an excellent job of finishing it Indy. Now the fun starts with weathering and distressing. The part I like the best. I'll be bringing the coffee, so to speak.
We started the test-assembly today so we could do the final painting and weathering. I found a cool Imperial recruitment poster on-line and printed it up and weathered it to paste to one of the walls:
Many layers of paint (and coffee) to get the coloring we wanted:
Carefully weathering the door:
Here's the finished door:
One week from now we will do the final assembly...
Got the IG-88 / flame tube pepped last night - two coats of resin today and fibreglassed inside, then poured in some rondo for the bits that were too hard to reach properly with the fibreglass. There's a few bubbles in the card from where the resin cooked too hot in the curing cabinet, but they'll sand out OK. If not, it'll just be covered with weathering.
Drilled the holes just now. Indy - they're 2 1/8" and 1" diameter, just so's you don't have to convert...
Next up is some black paint inner and outer, if there's some in the shed, followed by weathering. Might brush on some aluminium powder, then a bit of sooty wash.
I know it's missing details, but the next one will be better prepared. I might reshape the top of the mesh just under the angled top - there's a slight curve that's missing on this one. Plus I'll add a heap more rondo inside before glassing.