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I began with a 1/8' styrene sheets that I cut into all of the major body panels using nothing more than a box cutter and a ruler.
The body panels were than cleaned up with a little sand paper. Most of my sanding needs were met with a simple block of wood and sand paper, but other times required a belt sander.












































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If you have any more questions I'd be glad to answer them.
I'm glad to see that people have been brain storming and throwing material ideas around. When I posted this instructable I didn't want people to go out and build the same ship I built but inspire them to do their own thing and it seems like that's exactly what’s happened.
If you do decide to do a project like this I have to warn you it’s not a small task I will take over your life
But its worth it
Anyone interested in finding out more techniques would do well to poke around on miniature wargaming websites. Scratch-building models, vehicles, and scenery are all staples of the wargaming community that have been well covered in both broad and narrowly focused articles and tutorials. You're sure to find some good information that can be applied to any modeling project, as well as game-specific conversion work.
My own experience, as well as that of countless wargame scratch-builders says differently. Have you tried adding reinforcing ribs in large voids and/or pinning joints with toothpicks when gluing? Sure, you can break the stuff if you try and bend it over your knee, but it's far more durable than you give it credit for being.
That said, your point about "for sale" signs is totally valid. When you don't need a clean finish and the exact thickness is unimportant, those signs are a great way to get larger sheets on the cheap.
Thepelton's warnings should also be heeded. CA glues (Superglue, Krazy glue, etc.) will melt the foam in foamcore, but is fine on the paper facing or sheet styrene (same with the propellants in most spray paints/adhesives). PVA/white/wood glue is pretty much the only thing that I always assume won't cause an issue. Everything else, I check it, first.
The fiber optics are a nice touch. Lights make or break models like this.
Increase thickness by layering and laminating (super gluing the cracks).
For odd shapes find a form (preferably wood forms) and use a heat gun to lightly melt/form the styrene. Another alternative for more advance people is to use a vaccuformer (DIY here at instructables).
Very cool follow along but I have to agree with some. On your next one a more detailed step by step would be better.
it is lite, but it can warp if large unsupported areas are used. just another material to consider. hobby lobby has it in poster size sheets. lots of colors too. i make frames to hold model planes while the glue sets up.
And, of course, about general epicness...