Introduction: K'NEX Star Wars Millennium Falcon

"You've never heard of the Millennium Falcon?"

- Han Solo

If so, that is about to change! Because in this instructable I will show you how I made my K'NEX Millennium Falcon from the original Star Wars movies! This spaceship was long on my list of things to build, as the Falcon is a really one of my favourite ships due to its somewhat asymetrical, flat and round shape. I am a Star Wars fan myself and I've already made some of the other spacecraft I love out of K'NEX, like the Imperial Lambda-Class Shuttle and the Rebel B-Wing Starfighter. Currently I'm working on a TIE-Fighter, a collaboration with Linkin_J_Knex. In the future I plan to make: X-wing, Y-wing & Jedi Starfighter, Walking AT-AT and a big Imperial Star Destroyer.

But let's talk about the Millennium: it includes 1395 pieces, and the model is roughly on 1:50 scale. The original ship is namely 26.7 meters (87.6 feet), while this model is 53.4 cm (21 inch) long. It has several functions such as moving Quad laser cannons, retractable Landing gear and a boarding ramp. You can either play with it, by holding it in your hand, or you can display it on the stand. It's not lightweight: it weighs 1.7 kg (3.75 lbs). The model was built in about 20 hours total, spanning several weeks of designing. With each step, I will tell how I made the part.

The steps are accordingly to this list:

  1. Things & Parts Needed
  2. Landing Gear & Base Structure
  3. Side Elements & Boarding Ramp
  4. The Hyperdrive!
  5. The Front side
  6. The Cockpit
  7. The Top Cover
  8. Antenna & Quad Laser Cannon
  9. Display Stand & Enhancements

Each step has an appropriate Han Solo quote to keep the theming right ;)

Step 1: Things & Parts Needed

"I have a good feeling about this..."

Skills:

I'm not going to give the set an age-range, but it is for medium-to-experienced builders. The steps should be able to follow. If you're having trouble, please ask in the comments-section

Set specific pieces:

Beasts Alive Bronto Building Set, Item: # 34483 Price: $28,-

  • 45x 4-way Black connector (otherwise, the model will become green-ish)
  • 7x 5-way Dark grey connector

Knex pieces: Buy at K'NEX User Group / K'NEX spares

Rods:

  • 219x Black rod (16 mm)
  • 184x Silver rod (32 mm)
  • 11x Flexible purple rod (32 mm)
  • 57x Blue rod (52 mm)
  • 6x Flexible blue rod (52 mm)
  • 26x Dark grey rod (86 mm)
  • 2x Flexible orange rod (86 mm)
  • 1x Red rod (128 mm, from the Beasts alive set)
  • 1x Grey rod (190 mm, from the Beasts alive set)

Connectors:

  • 9x 8-way black connector
  • 31x 7-way blue 3D connector
  • 65x 4-way silver 3D connector
  • 141x 5-way grey connector
  • 61x 3-way dark grey connector
  • 30x 2-way (V-shape) grey connector
  • 33x 2-way (long-shape) brown connector

Clips/Other:

  • 116x Clip with hole end dark gray (1-way connector)
  • 12x Hinge blue part
  • 14x Hinge black part
  • 46x Metallic spacer (1½ width)
  • 23x Blue spacer (½ width)
  • 94x Black clip with rod end
  • 7x Metallic grey clip with rod end (for aestethic purposes)
  • 23x Clip with Ball end
  • 1x Clip with Socket end
  • 13x Clip blue
  • 6x Interlocking clip Tan/brown
  • 8x Ball and socket Large
  • 4x Clip with Splice end Orange

Gears:

  • 1x Gear small Push-on Grey

Panels:

  • 3x Tri panel mini blue
  • 8x Tri panel mini silver
  • 2x Tri panel small silver

Wheels:

  • 1x Wheel 25 mm Open centre black
  • 2x Hub Motorcycle Grey
  • 2x Hub/Pulley Medium
  • 4x Hub Racing wheel 37mm Grey (if you have/buy them, I would take Black)
  • 6x Tyre Small

Micro K'NEX: Buy at K'NEX User Group

  • 42x Connector 4-way Light Grey
  • 1x Connector 8-way Metallic blue with 6mm hole
  • 13x Rod Dark Grey (40 mm)
  • 16x Rod Black (14 mm)

Other:

  • 2x small pieces of scotch tape
  • 2x miniature elastic bands (1 cm / 1/4" diameter)
  • 1x A4 Size paper and a colour printer

This time, I have not included a separate list for the Display stand, as its parts are common and it doesn't require a significant amount, in comparison to the Falcon itself. The listed items are both for the model and the Display.

Step 2: Landing Gear & Base Structure

"Here's where the fun begins!"

First, you start off by making the bottom circle and the quad laser cannon, after which you attach the landing gear. During the whole instructable, the model will rest on the landing gear. If you want to put it on the display stand, you have to retract it, as shown in the video from the Introduction.

Although it is the first step of this ible (for building reasons), this part was not the first part I made while designing. I started from the Hyperdrive (seen in Step 4) and then made the middle column (cylinder), to which everything is attached. This gives the model it's strength, so that you can lift it without being scared that the model brakes. I modelled the landing gear as best as possible to the original spaceship. Normally, the Falcon has 7 "feet", but as I wanted to make them retractable, I had to reduce this to 6: The front one is missing.

Step 3: Side Elements & Boarding Ramp

"Don't worry, she'll hold together... You hear me, baby? Hold together!"

In this step, you will start by making the top-half circle, where in Step 8, the top quad laser cannon will be attached. Then, the rear end will be prepared, so that later the Hyperdrive engine can be attached. Then, the front ends are attached, in the same manner. Then the right side element is made and attached, after which the boarding ramp will attached. Then, the left side element is made. It is the mirror of the right, apart from the fact it does not have a boarding ramp there.

From the middle column, I started to design the left and right side elements. These have a specific 6-edge shape, which was quite challenging to make. Additionally, the end has a round shape, which is made by a medium wheel hub, clamped within 4 rod ends. It was a lucky, but sturdy fit!
The boarding ramp I made later, after the important shapes were made. It uses a technique where a 5-way connector is clamped between 2 clips.

Step 4: The Hyperdrive!

"It's the ship that made the Kessel Run in less than 12 parsecs"

In this step, you first make the thrusters, then you create a structure around it and add a ventilation port (number 2 of 6) Then you attach it to the back of the Falcon (which can be tricky) and attach it to the sides as well.

The Hyperdrive is a very recognisable feature of the Falcon and has a specific arched shape. That makes it also one of the hardest parts to make of the model. Therefore, I designed this part first. When the Hyperdrive was made, it also defined the scale of the model: Big!

Step 5: The Front Side

"Never tell me the odds!"

First, you will make different parts of the frontside of the Falcon. Essentially, both sides are their mirror image, apart from a few pieces. It becomes one big piece that is later attached, as whole, to the ship. This can be a bit tricky, as the front flaps have to be closed. (That is why they were left unattached to each other in the first place).

I made the front parts relatively quickly after I made the Hyperdrive. Surprisingly enough, it wasn't hard to get the angle right, or perhaps I was lucky by finding something nice at the second trial. In the next step you will attach the cockpit.

Step 6: The Cockpit

"Hurry up, silver rod!"

In this step, you will first make the part to which the Cockpit is attached (in the spaceship, this is a kind of walkway for pilots/passengers). Then you will make the Cockpit itself, and attach it with two big ball-joints.

It took me the most time to get the cockpit at the correct angle. I found a way to do this by having big ball joints attach to the Front and the right Side Element. I knew I wanted to have a medium sized wheel to create the same round effect of this walkway. I was probably going to make it with paper, which I finally did. But, I also wanted to make the cockpit out of paper. One afternoon, I started making something with Micro K'NEX (as I had already made the Antenna with micro K'NEX) and this was the result. I'm quite satisfied with how it looks. It still has a sort of "window" where you could imagine Han and Chewie sitting :)

Step 7: The Top

"I think my eyes are getting better. Instead of a big dark blur, I see a big light blur."

This is the second-to-last step to finish the Falcon, where you will make and attach mostly flat sides to the Top (actually the four quadrants) of the Falcon.

Quite soon after I finished the Hyperdrive, the centre column and the Front, I started making the back cover. First I was thinking to also cover the bottom, but as the retracted landing gear take in quite a lot of space, I decided not to do this. The third part to make was the quadrant where the Antenna sits at, it was more easy than I thought, altho it is not completely accurate to the original ship: The round shape is overlapping a wheel. The part covering the hole near the cockpit, I made last.

Step 8: Antenna & Quad Laser Cannon

“Hokey religions and ancient weapons are no match for a good blaster at your side, kid.”

In this step, you make the Antenna (from the original Triology, not the more rectangular shape from the new VII movie) and after that, the only K'NEX guns I'll make: The Quad Laser Cannon. It can be moved up and down and swivelled left and right by a joystick. Then the Millennium is done!

I quickly knew I had to work with something else than regular K'NEX, if I wanted to create the round shape of the Antenna. This came down to micro K'NEX, which I do not prefer, but it looked good. First I had a different kind of movable cannon, but it was very fragile. When almost done, I changed it to this version that is easy to play with, when you're playing with the Model.

In the next step, I will show how you can add a paper piece to enhance the looks. Furthermore, you can choose to display the model, when you are done playing.

Step 9: Display Stand & Enhancements

"Great kid, don't get cocky!"

In this very last step I will show how to make the Display Stand, as well as a paper cutout that you can stick to the model so it looks slightly better. The final 4 pictures show how you can put the Falcon on it's Stand, and the final model.

The Display Stand is always a very custom thing to make, and in the case of this 1.7 kg model, it has to be sturdy! The only real attachments are 2 rods, that are put slightly at an angle in both Z and Y-axis. That gives the model a more "flying" look. Further more, 2 supports are added on the side, so that the Falcon won't wobble on the rods. But even without them, the model is so well balanced that it stays put. I have created a .pdf-file that has the fact sheet and the paper cutout. My inspiration for the information plaquette comes from the LEGO Ultimate Collectors Sets, but this time, I made it my own, from scratch. I only used MS Word & Paint, it can be seen how I made it here.

If you built it: great job! I would like to see how it looks. Also if you used other colours, I'm curious what the result is. Thank you very much for scrolling through or visiting this ible! If you want you can give suggestions for Star Wars models that I can build next, if they are not already on my list!

"May the force be with you"

GWorks

Comments

author
Ethan1023 made it! (author)2016-06-25

Hey, GWorks, that helicarrier that I'm building is pot. I'll post an "ible" 'bout it, but I can't do instructions (cuz it's falling apart as we speak).

author
Ethan1023 made it! (author)Ethan10232016-12-21

Correction: kaput.

author
GWorks made it! (author)GWorks2016-06-25

Hello again :)
("is pot"? Never heard of that expression xD)

Well, try to make some nice pictures of it, and when you upload them, also write what went wrong. It could help some people here on instuctables to perhaps improve your build :)
Think from their view, what do they like to see? And perhaps you can still break it down in parts :) Good luck

author
Ethan1023 made it! (author)Ethan10232016-06-25

Umm... I went ahead an took it apart. The main reason it was falling apart was that my dad asked me to take it apart (as it was very big and cumbersome), I was frustrated because loose pieces of sticky side up duct tape attracted (very) unwanted crickets in our basement, and it's size made it break whenever I picked it up.

author
Ethan1023 made it! (author)2016-05-17

How is your next model coming?

author
GWorks made it! (author)GWorks2016-05-17

Here you can see what I'm working on: https://knexflux.net/project-progress/k'nex-star-w...

But I won't post any ible in May... I'm busy with other things. But I have two additional plans >:)

author
Ethan1023 made it! (author)2016-05-07

In addition to the helicarrier that I'm building, I'm also planning on building a Quinjet, Malekith's flagship (Thor: The Dark World), an Elven stealth ship (same movie), a Hunger Games Capitol Dropship, and a Hunger Games Capitol Stealth bomber.

author
GWorks made it! (author)GWorks2016-05-07

I'm not into comic stuff :) But I know the hungergames things. Well, good luck

author
Ethan1023 made it! (author)2016-05-06

I've created a prototype runway (a section) using a frame (out of K'Nex), paper, and a hole puncher.

author
GWorks made it! (author)GWorks2016-05-07

Nice :)

author
Ethan1023 made it! (author)2016-05-04

I'm not very far. I wouldn't have started without first creating the 4 rotor assemblies. The rotors are a white connector with blue rods on all eight sides.

author
GWorks made it! (author)GWorks2016-05-04

Super :)

author
Ethan1023 made it! (author)2016-05-03

Quick question: I'm making a model that requires a runway, so I wanted to use connectors and rods. When I used that, I got 2 grey rods length and kind of ran out of pieces. How do you make the pdf uploads for the creations?

author
GWorks made it! (author)GWorks2016-05-03

You're probably making the Helicarrier, aha :)
Are you now also having a question about the runway? because that's unclear to me from your message. (It's a little confusing, to say the least)
How I make my pdf's for the display and additional stuff?
Everything is made and put into position in MS Word 2010, then I save it as pdf.
If you have MS Word 2007, you can use something like pdf Creator http://www.pdfforge.org/pdfcreator
And once I make an 'ible, I upload them just like I would with photographs :)

author
Ethan1023 made it! (author)Ethan10232016-05-04

Thanks a bunch. That's exactly what I'm building. The runways (both of them) utilizes a lot more pieces than I'm comfortable with using, plus they have extra details like markers and the S.H.I.E.L.D. symbol.

author
GWorks made it! (author)GWorks2016-05-04

So you asked because of the markers and the logo?
Well, if you're uncomfortable: use less :P okay, perhaps that's easier said than done... but maybe you can make a compromise :) and if you want to print the runway stripes, maybe you can do it completely printed, on top of a simple box-frame? (only suggestions)

Another option is to scale down. I'd advise you to make the most difficult thing first! (I think that are those round, hovery-thingies on the sides? not a flat, straight runway? But I don't know how far you are with your build)

author
Ethan1023 made it! (author)2016-04-15

The Millennium Falcon? The only ship to make the Kessel Run in less than 14 parsecs?

author
GWorks made it! (author)GWorks2016-04-16

TWELVE!
Fourteen... *sigh*... kid's these days...

author
Ethan1023 made it! (author)2016-04-09

Right. I wasn't aware that you could delete posts. Have any of you guys seen "The Force Awakens"?

author
GWorks made it! (author)GWorks2016-04-09

Great! Thanks a lot for cleaning up!
And yep, I saw it somewhere in December. Actually I'm not so into the whole story (It took me up to until 2015 to realize the prequels are so full of political nonsense) And also the original series have many flaws. But I just like Star Wars because of the theming, the scenery, the way it was shot, some characters etc. And not important: the vehicles ;)

author
Ethan1023 made it! (author)2016-04-09

If so, just tell me. I have seen it, but I don't know who hasn't, so you might give spoilers.

author
Zombiekiller-93 made it! (author)2016-04-01

Awsometacualar GWorks

author
GWorks made it! (author)GWorks2016-04-02

Gratitudious, Zombiekiller :D
(Thanks!! ;)

author
Zombiekiller-93 made it! (author)Zombiekiller-932016-04-02

Thats alright, what did you think of The Force Awakens

author
GWorks made it! (author)GWorks2016-04-02

Ah yes, when I posted the Lambda it wasn't out yet.
Hmm, it was a nice movie, good acting and reasonably good start for a triology, but I think there were too many parallels with "A new Hope".
And they shouldn't have showed Luke at the end of the movie :P What did you think about it? (I'm also assuming you've seen it)

author
Zombiekiller-93 made it! (author)Zombiekiller-932016-04-02

Yes I did see it with a group of friends on the 20th December 2015 and well from my opinion it was good and alot of fun. Did easily notice the parallels with A New Hope and waiting awhile for any of the original characters to appear but I guess they were put aside to make way for Rey, Finn and Ren. When Han died on that big screen, my heart and soul dropped completly. Be interesting to see where Episode VIII and IX go.

author
GWorks made it! (author)GWorks2016-04-02

Glad you enjoyed it ^^
Han's death wasn't really a shock... a bit sad tho. Curious what will happen to the new characters. Chewies reaction was gold tho...

author
Zombiekiller-93 made it! (author)Zombiekiller-932016-04-03

I really hope its either Rey, Finn, Leia or Luke that kills Ren in Episode IX

author
Linkin_J_Knex made it! (author)Linkin_J_Knex2016-04-09

Sorry to nose around again, but I enjoyed the film. Im sorry to say that's the first star wars film I've watched xD I've seen chunks of other ones but could never get into them. Im no big star wars fan (although I sort of wish I was) but I love star wars nonetheless :)

author
Ethan1023 made it! (author)2016-04-08

Glitch. I am so sorry. There was this thing that the "Post Comment" button wasn't responding, so I pressed it like 6 times, before it responded. It apparently was working the whole while, I just didn't see it. Sorry 'bout that.

author
GWorks made it! (author)GWorks2016-04-09

I know it can happen, so don't worry about that. but can you try to delete your double comments? Also replying to this comment helps for other people who want to follow this conversations, but I don't know how hard it is to reply to my message from the device that you are using.

author
GWorks made it! (author)2016-04-08

Dude, how often did you hit that "reply" button?! xD 6 times I believe...
Err... far too complicated? even to complicated to take a picture of? They say a picture tells a 1000 words... :/

author
Ethan1023 made it! (author)2016-04-08

Actually, I"m not posting instructions about it, for the reason that the 2 "arms" that connect the cockpit to the main wings are far too complicated to post instructions and pictures about, let alone try to tell everyone how to build it. I"m still proud of it, though.

author
Ethan1023 made it! (author)2016-04-07

I will, once I can get the camera pics uploaded onto the computer.

author
GWorks made it! (author)GWorks2016-04-08

Alright, I'm curious for the result!

author
Ethan1023 made it! (author)2016-04-07

I'm building a First Order TIE Fighter right now. Very hard to color code properly.

author
GWorks made it! (author)GWorks2016-04-07

I've found a way to do it, together with Linkin_J ^^ Hopefully I can make pictures this afternoon, then the instructable will be finished soon.
Are you too planning on making an instructable about it? :)

author
Linkin_J_Knex made it! (author)2016-04-02

Its stunning! I loved the video too! Hype for your next ible :D

author
GWorks made it! (author)GWorks2016-04-02

Thanks. I finished the TIE today! (And broke down the Millennium, since I needed the pieces) I also started working on a Speederbike, and some parts for the Slave I
But ofc, the AT-AT and the AT-ST are also still on my to-do list.

author
Linkin_J_Knex made it! (author)Linkin_J_Knex2016-04-03

Great! :D When will you start work on the tie fighter ible?

author
GWorks made it! (author)GWorks2016-04-03

I have been neglecting other things (my graduation internship, private stuff) too much lately, so they have priority now. The TIE fighter I could photograph within a week.
And again this morning I worked on the Slave I... addicting. And the colours push me to new limits (It's metallic green and grey and brown... and in a difficult shape... ouch)

author
Linkin_J_Knex made it! (author)Linkin_J_Knex2016-04-07

Btw I voted

author
GWorks made it! (author)GWorks2016-04-07

Thanks, but I'm not expecting to win, which is fine :P also check out the other participants, there's some cool ibles there!

author
Linkin_J_Knex made it! (author)Linkin_J_Knex2016-04-07

Okay :)

author
Linkin_J_Knex made it! (author)Linkin_J_Knex2016-04-07

Also, spelling mistake step 5. "ta" instead of "a"

author
GWorks made it! (author)GWorks2016-04-07

Happy sone's nosing around for typos like that :P I'll correct it

author
Linkin_J_Knex made it! (author)Linkin_J_Knex2016-04-07

Yw :)

author
Linkin_J_Knex made it! (author)Linkin_J_Knex2016-04-03

Okay I understand and I'm excited for the other builds :D

author
Jedi_zombie85 made it! (author)2016-04-04

As already stated, top work, deffo one of the best knex projects ive seen in a long time

author
GWorks made it! (author)GWorks2016-04-04

I'm trying my best for high quality and making things people and myself like ;)
Any ideas for other Star Wars stuff to build? Suggestions are welcome!
And thanks!

About This Instructable

4,385views

58favorites

Bio: Hello! I am mechatronics graduate and have always had a passion for making things. This started at an early age with LEGO and K'NEX ... More »
More by GWorks:K'NEX Anakin's PodracerK'NEX Sebulba's PodracerK'NEX Motorized AT-AT From Star Wars
Add instructable to: