Making the Star Wars Millennium ALUMINUM Falcon

The all-aluminum Millennium Falcon, true to my mantra: “If it’s worth doing, it’s worth OVERDOING!” While everyone can recognize this as the model of the Star Wars Millennium Falcon piloted by Han Solo, the creatives at C4 Labs have named it the YT-1300 Lightfreighter… I’m sure you can imagine why. I made this version in honor of the current movie - Solo: A Star Wars Story
My Friend and fellow KZbinr (links below) Jose provided me with the files for this project… This has been a year in the making, and over a month in execution. The original files were designed by C4 labs (link below) to be laser cut but that proved to be only “close enough”. After scaling up the drawings, I had to make the parts “waterjet friendly” which ended up taking an extraordinary amount of time.
Jose has a very nice video making a laser cut wood version of the Millennium Falcon, although a much smaller version, much more detailed since the laser offers engraving capabilities that the waterjet does not. Be sure to check the links below for Jose’s video.
Using about ¾ of the 4’x8’ sheet of aluminum, seemed reasonable at first…. Until I finished the assembly! At 21lbs it actually seems a little bit too heavy… but awesome none the less. I may have gone a little too far with this one, but then again I usually do. I don’t think I’ll do another one like this again, partly because of the cost.
Lastly, I know some of my viewers will be interested in knowing what this cost to make - A LOT!!! If you want to know more about the cost, I added a bonus video clip to the end of the video that discusses it in more detail, jump to 9:17 for more info.
The material - 3/16” thick 5052 aluminum
Cutting time - 4.25 hours
Preparation and Assembly time - 18hours (over the course of several days)
File preparation time - approx. 40 hours
Stats: 19.5” long and 21lbs (YES IT IS VERY HEAVY)
Please do not ask me for the files, they are not mine to give away.
My waterjet info video - • CUTTING on the Waterje...
Jose’s YT-1300 LightFreighter video - • Assembling a Laser Cut...
City Aperture channel - / @cityaperture
C4labs website - c4labs.net/

[@lowellhouser7731]

"What the hell is an ALUMINUM falcon?"

[@RayMAKES]

This guy gets it!! I may have been too literal

[@doubledarefan]

Alumillennium Falcon.

[@RayMAKES]

Try saying it 5 times fast

[@emmanuelayo8339]

really amazing !! i've got some star wars vessels too but not in aluminium

[@RayMAKES]

Emmanuel!! glad you like it... your 7 gear is almost finished!

[@HeathKnuckles_Tasty_Timber]

Ohhh that’s awesome dude!! That’s looks great Ray!!

[@RayMAKES]

Hi Heath!! thanks, glad you enjoyed it!

[@CheddarVG]

Palpatine got his answer.

[@RayMAKES]

Truth

[@AwesomeWoodThings]

That's crazy! I LOVE it!!!

[@RayMAKES]

Thanks Matt, Glad you liked it.

[@ESCAGEDOWOODWORKING]

Amazing work!!!

[@RayMAKES]

Thanks Eloy

[@ManCrafting]

That's insane Ray! Great job. I really like the bead blasted look.

[@RayMAKES]

thanks Chad... i actually have no idea why i made it

[@WildmanTech]

Good job. I never would have thought to use CA glue.

[@RayMAKES]

Thanks, CA glue in this case is better than welding

[@alexandrevaliquette1941]

For the same price, you could buy yourself a small personal 3D printer (200$), print it with plastic or a 80% brass filled PLA or other metal filled filament (12-80$ per kg). Note that you will not print 100% full, you might print it at 20%, the rest will be empty space such as internal desk, corridors, mechanical room, etc. You would get all great 3D details such as computer, chairs, laser, knobs, moving mechanism, moving doors, turets, figurines, etc. Instead of a flat slate. Great video, thank you for sharing the price tag evaluation. Thumbs up!

[@RayMAKES]

I have a few 3d printers, but the goal was to make it in metal... even though it was crazy expensive. Glad you liked it.

[@alexandrevaliquette1941]

Ok, thanks for the answer! I did not know you already own a 3D printer. Now I better understand the personal challenge here. By the way did you ever try the 80% mass (33% volume) metal filled PLA fillaments? Of course it will not be as "full metal" as yours, but you can increase the detail level substancially and still have that metal weight and feel. I never used this fillament, only saw a few video on it. Yep, Another project!

[@RayMAKES]

Never used that filament either. If you are curious I have a few 3d printer videos on my channel, here is the link to the playlist 3D Printing: kzbin.info/aero/PLjb5twhxLLcIcjTXt9YtpdiFx_iGwLmQ9

[@alexandrevaliquette1941]

Ho, I did not realize it was you, the same guy! As you know by now, I went to your channel, look at your 3D printer video and put somme positive comments! You seem to have access to larger and broader equipment than me. Have a great day, smartman!

[@RayMAKES]

Ha, thanks.... I've been working on videos for about 2 years now, gkad you are enjoying them

[@danthemakerman]

This is pretty badass Ray! You need to make a stand for it now.

[@RayMAKES]

It's designed to hang.... but I don't think 21 lbs is a good idea to hang from the ceiling

[@ronaldhotboy]

That's freaking amazing brother!

[@RayMAKES]

thanks Ronald!! its been a while. i got a notification of your last video but when i went to see it, it was gone! i hope you are alright!

[@ronaldhotboy]

Ray MAKES thanks a lot brother I was in a motorcycle accident I am okay my lower back hurts a little bit. I had to remove it because the lawyer is still looking into the information

[@leksey7870]

Interesting unit, I liked it!

[@RayMAKES]

Hi Aleskey! its been a while, im glad you liked it!

[@robertevans6481]

"""DUDE""" of the chain.....

[@RayMAKES]

Thanks Robert

[@TJSWOODWORKINGSHOP]

Hey my brother I'm back PAPA,I don't know what to say, You the man awesome project I love it later :)

[@RayMAKES]

thanks TJ, hope you are doing better!

[@user-zj2mb3sp3x]

Was this farscape music? I miss that show.

[@RayMAKES]

It was a KZbin file

[@ManBearPig1968]

That really is an Aluminum Falcon!....come on I know there are some Robot Chicken fans out there. " robot chicken, star wars, the emperors phone call" on KZbin. Thanks Ray great project , loved it! I'm a huge Star Wars fan and this is very cool. Might have cost less to build a real YT-1300 Millennium Falcon.

[@RayMAKES]

oh yeah, i m a fan too! it was expensive to build, but so far, its the only one!

[@bruner]

That was amazing! I am surprised that using a glue is "strong" enough... Do you think the glue will last over the ages ?

[@RayMAKES]

thanks, the glue is really just insurance on most of the pieces and the ones that are loose fitting are so small that they wont break off. i keep it near my desk, and it always get alot of attention. i do think the glue will last without a problem

[@davidvarnes7708]

They made an Aluminum Falcon. Who's THEY?

[@RayMAKES]

That would be me

[@danthemakerman]

I'll give you 50 bucks for it and you pay the shipping.

[@RayMAKES]

Lol, that sounds fair

[@anthonyenos8677]

How many us have a water jet that's at least 100k.He must not have Kids.Oh I forgot his Selenium Falcon is his kid.

[@RayMAKES]

first of all, a water jet like this is around 600k. second, no i dont have kids, which is why i can afford to have a waterjet. third, we all have to live with our choices in life... im very happy with mine. i see you like to complain about the things you dont have... i suppose thats also a choice

[@FischOderAal]

All the time I had to think about this: kzbin.info/www/bejne/aXeUlWaHjNisoZI

[@RayMAKES]

lol, big robot chicken fan here as well