Palitoy Death Star repro

stealthboy

stealthboy

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Hello all! I'm beginning a project to make my own Palitoy Death Star.

Yes, I know Replicator has printed the cardboard pieces in the past, but it's sold out, so I want to make my own. So far I have scans of all the cardboard pieces, and I have found a few 3D files for the clips and the garbage chute so I can 3D print them myself.

I have some questions, and I hope some folks here can help.

1) What are the dimensions of the Palitoy Death Star? I have images, but the scale is not apparent.
2) Is the thickness of the cardboard more like packing box thickness, or like Cloud City payset thickness? I think it's the former.
3) I was planning on printing images on adhesive-backed vinyl sheets - does this sound like a reasonable plan?
4) Any reference material for the top gun turret? I found a 3D file for the canopy, but nothing on the base circular part.

Thanks in advance for any help, source material, or good all-around advice.
 
I can at least help with #2:

The construction of the cardboard for the walls and floor of the Palitoy Death Star have best been described as like a board game. It is not corrugated cardboard like you find in a box. If you bought the playsets from the Solo line, it is the same material as those (I have never owned the Palitoy Death Star either, but I have looked into it a great deal.)

The specific name for that type of cardboard is chipboard, but you have to be careful as chipboard comes in varying thicknesses and weights.

Edit: and 9 years ago I designed a 4-sided "chipboard" Death Star that was inspired in part by the Palitoy Death Star:

DS20 Side 1.jpgDS20 Side 2.jpgDS20 Side 3.jpgDS20 Side 4.jpg
 
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I want to make one out of plastic. Years ago there was a toy called Moppet's secret dollhouse... My sister had one would make a cool Death Star if you could 3-d print one.
 
Booster Terrik said:
Have you seen this?

Doesn't have the Palitoy clips to hold the sections together though but it does appear to have the turret canopy and guns.
Click to expand...

The walls look way too thick on this one. I think I'd have better luck with some heavyweight chipboard and printing my own. But good call on the clips. I also saw a custom repro canopy on eBay as well.
 
Found this size info on an old post at starwarsforum.co.uk:

"As luck would have it, I've recently had reason to measure my loose one. The base is 60 cm in diameter, and the height of the cardboard is therefore 30 cm. I didn't bother adding the clips, seat, canopy or X-Wing guns when measuring, but I would allow another 4 or 5 cm or so on the height"

If anyone happens to own the Death Star playset, can you measure the thickness of the walls? I would guess something close to 1/8th of an inch.
 
Ok, I'm pretty sure it's 2.5 to 3mm thickness of the chipboard, so I'm looking at some sources for 100 or 120 pt weight stock.

I also need some mirror / silver finish adhesive vinyl sheets for the bottom of the central shaft. Found a roll of that.

I came across a great set of old videos from Toy-Polloi where he did some restoration of a vintage Palitoy Death Star, and at the end provided some bonus measurements of all the pieces.
  • Top gunner disc: 15.1cm diameter
  • Gangway top to bottom (unfolded): 26.9cm
  • Trash compactor sliding part - measured along hinge: 20.5cm
  • Side support piece - bottom of pillar to top: 28.4cm
  • Two large main walls - height: 29.2cm
  • Base across hinge: 59.8cm
I found 3D files for the clips (black PLA), the trash compactor chute (black PLA), and the top canopy (I found some clear PLA for that). The cannons are just X-wing cannons as Lobotscomb mentioned. The only thing remaining to be sourced is something for the gunner round base part that was originally vacuum-formed.
 
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If you take the print files to someplace like Staples, will they be able to print them on a large format printer so that you could actually just glue them down?
 
Lobotscomb said:
If you take the print files to someplace like Staples, will they be able to print them on a large format printer so that you could actually just glue them down?
Click to expand...
It's an idea... but I'm going to try to print my own on smaller 8.5x11 sheets and pattern them together. Two reasons: 1) I feel like printing directly on adhesive-backed vinyl is better for a smooth surface; I've had bad experiences with various glues and spray adhesives trying to get a good surface sometimes, and 2) It would probably be ~$100 to print what I need on a large-format printer. That's a bit too much for me right now.

There is a YouTube video I found of someone who took the files to Staples or something and printed them, then proceeded to use double-sided tape to tape them down to foam core board. Not a good finished product IMHO and lacked polish, and he spent $75 on the print. The store also messed up the sizing of two of the images (some people don't pay attention to dpi and image print resolutions).
 
It has begun. 3D printed my first part.

death_star_chute.jpg

EDIT: For future reference, here are the 3D files I am using:
EDIT again: The clip file above is really difficult to print and get the supports out without breaking. I found this file much better (and as an added bonus it's available as a free download):
 
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A few updates:
  • I reprinted everything on gloss vinyl sheets because the matte didn't match the original Palitoy finish
  • Printing the canopy with clear PLA was interesting - it's more of a translucent frosted look but I think it works
  • I have the 6 figure stands now as well (must be complete!)
  • Waiting on the chipboard delivery from a local paper company, should be here this week
  • I have the adhesive chrome vinyl sheet for the mirror sticker at the bottom of the central shaft
  • Still have no idea about sourcing the gun turret bottom part in a reasonable way - there is one eBay 3D printed source I found but the shipping from the UK is insane, so I'm still looking around. I'd prefer an actual vac-formed piece.
IMG_9050.jpg
 
jedi_ds said:
Looking good, where are you at on cost?
Click to expand...

Currently I'm at $91. This includes a full spool of clear PLA filament, pack of 20 Star Stands (only need 6), 3D file purchases, chrome vinyl roll, gloss vinyl sheets, and chipboard. The only remaining expense would be for the gunner turret base.

To build a second one I would just need another order of chipboard ($35), since the other supplies were way more than I needed.

This weekend I should have the first walls constructed.
 
First piece has been constructed.

I ended up buying one original cardboard part on eBay so I could really get a sense for the thickness, color, finish, and construction of the cardboard panels. The chipboard is definitely 80pt thickness (about 2mm).

I chose to start with the sliding trash compactor piece because it is one of the more intricate with the bend in it and the various cuts around the panel. It's made up of four printed vinyl pieces. I think it came out pretty well for my first attempt. I intend to tackle the two large intersecting panels next.

IMG_9066.jpg

EDIT: Here's a second picture of the back of the piece when it's flatted out.
IMG_9067.JPG
 
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That looks good. I think you have nailed the finish! Looks just like I remember it.
 
stealthboy said:
A few updates:
  • I reprinted everything on gloss vinyl sheets because the matte didn't match the original Palitoy finish
  • Printing the canopy with clear PLA was interesting - it's more of a translucent frosted look but I think it works
  • I have the 6 figure stands now as well (must be complete!)
  • Waiting on the chipboard delivery from a local paper company, should be here this week
  • I have the adhesive chrome vinyl sheet for the mirror sticker at the bottom of the central shaft
  • Still have no idea about sourcing the gun turret bottom part in a reasonable way - there is one eBay 3D printed source I found but the shipping from the UK is insane, so I'm still looking around. I'd prefer an actual vac-formed piece.
View attachment 517185
Click to expand...
How are the connecting clips holding up?
I thought I saw a 3D canopy model out there somewhere. I'll have to check my other laptop when I get home.
 
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