Harrison Ford as "HAN SOLO" in STAR WARS, 1977

If it's one character probably most of us wish would be
done well in 1:6 scale from the Star Wars films, it's gotta
be Harrison Ford as Han Solo (with Darth Varder a close
second, probably).  But Marmit only seems to do the
"hidden face" characters, and Hasbro...  well, you know...
In the end, I fashioned the buckles and
such from polystyrene, then primed and
sprayed it a metallic silver.

The metal studs on the belt were made
from aluminum using the same technique
I'd developed to make the studs on
Gladiator's straps, only smaller.

And finding enough reference phots on
the internet to ensure I was making an
accurate rendition was not a problem
either.  I spend at least half of my time
crafting these objects in front of the
computer, as all my reference images are
there.
And in case you were wondering, the buckle in the back actually works, so the belt
can come off and on without too much trouble.

Finally, I took the digital pictures you see here, tweaked them, and had a little fun in
Photoshop!  (Believe it or not, you can actually do a Google search for "photoshop
lightsaber" and get a whole bunch of websites that teach you how to do these effects.  
God bless the internet!)

The real hair head and the custom holster are what makes this figure truly unique.  
The time spent on each of these two things is ridiculous enough that I can't really tell
my friends or family, or else they'd think i was crazy.  (They already do, anyways...)  
Even with Gladiator, most of the parts, once sculpted, can be molded and cast in a
variety of materials.  With this Han Solo, however, this is not the case.  There are no
easy shortcuts to gluing on hair to create a realistic hairdo, and there's no other way
to make a holster belt with this level of detail than to simply invest a LOT of time...

So finally, I have a Han Solo worthy of display right along side my Marmit Boba Fett
and Stormtrooper sargeants.
I bought one of Hasbro's
(Kenner's) Collector's
Series Han Solos, but
was very disappointed by
the terrible likeness, not
to mention the poorly
articulated and poorly
proportioned bodies.  As
you can see in the photo
to the left, the clothes are
loose, the accessories
are bad, and the head is
over-sized.

They're doing a newer
version of Han Solo in 12" to be released soon,
but the picture I saw of it on the internet didn't
impress me.

So, once again, better to just do one myself.   
I'm planning on doing a Luke Skywalker
someday, and I'll probably use a Dragon body
for that since they're a little shorter.  So to
make sure Han Solo is proportionately taller
(I'm sure I'll be displaying them together at
some point), I decided to go with a Sideshow
body.
At first I was thinking that this would be
a really simple figure to do.  In fact,
maybe too simple.  So to keep things
interesting, and to continue developing
my skills in this format, I decided to
experiment with "real" hair.  As with
any figure, this was also motivated by
the fact that the longer the hair is on a
character, the less realistic it would be
"molded".

I started with a cast of my Indiana
Jones/Harrison Ford head, dremeled
away some of the thickness of the
sculpted hair, and in reshaped it to
provide a base for the craft fur I'd be
painstakingly gluing on.  I built it up in
layers, starting from the back, and
hairsprayed at the very end.
The pants on the Hasbro figure were okay, but there were two
noticable problems:  first, they were a little too short for the
Sideshow body's legs, so they kept coming out from the Dragon
boots I was using.  Secondly, the red stripes down the sides of the
pants were too thick and widely spaced.  Looking at reference
photos on the Hasbro box itself, you can see that the red pattern
should be a lot "tighter".

The shirt was also too short and kept getting untucked.  So, for
both the shirt and the pants, I decided it would be best if they were
both just sewn from scratch.  Luckily, I didn't have much complaint
for the vest, and decided to just use it as it was.
The belt is a
Dragon police
belt, I think.  I got
it from my
buddies at
Echobase Toys
in Temple City,
CA.  If you ever
need any part,
give them a call.  
Chances are
they'll have what
you're looking for.

The blaster is the
Hasbro version
as well, with the
handle modified
to fit the
Sideshow hands
a little better.
Aside from the hair,
which took a week by
itself, the most
time-consuming part of
creating this figure was
making a well-detailed
holster.

The idea, as always, was
to make one which, when
photographed, would be
completely
indistinguishable from a
photo of the actual prop.  
Hasbro's was far from this
ideal.
Again I combed the
fabric stores around
Los Angeles, and I
eventually found a type
of pleather, vinyl fabric that was
not too thick, and not too thin.  
And, it had to be in the right
color.  As you can see, I found
something pretty close, with the
right amount of thickness and
flexibility to approximate hide
leather at 1:6 scale.

I tried making the main buckle
using low-temp metals like
Cerrosafe, but it wouldn't capture
the detail required.