Han Solo in Carbonite

First, the "before" version....

I bought this at a Chiller convention for $10. The figure casting is usable, but the hands will need some serious work. The rest is a little rough, but nothing horrible. The carbonite casing will need to be totally rebuilt.

Step 1: Free Han from the carbonite block

The sides, top and bottom were removed on a table saw.

Step 2: Build a new carbonite block

The block is made from .040 sheet styrene. Overall dimensions are 5" wide by 13" tall by 1" thick. The original resin piece is only about 5/8" thick, not counting how far Han protrudes from the surface. The master pattern for the control boxes sits at Han's feet. Not shown: The sides have recesses in them for where the control boxes will sit.

Step 3: Build the control boxes

A close-up of the first stage master for the control boxes. A few of these will be cast up. Those will then be detailed up in various ways, then cast again. There are only two or three different patterns of detailing among the boxes, but 8 total boxes on the block. Also hard to tell in this photo, but the boxes are built to mount at an angle, just like the ones on the real prop.

A comparison with the blocks on the original piece as purchased. To say the originals are poorly defines is putting it lightly.

Here's one from the side of a real control box, taken at the Magic of Myth exhibit in New York this past summer. The one at the top that Leia uses to defrost Han is the same layout of squares and rectangles but is differently detailed otherwise. One or two of the other control boxes are also slightly different from this one.