Building an AMAZING Han Solo Carbonite Replica From Scratch

Prepare to journey to a galaxy far, far away—right in your own workshop! In this video, I reveal the entire DIY process of transforming expanding foam, resin, and plenty of PVA mishaps into a full-size Han Solo in Carbonite replica. From the early days of carving foam with a thousand craft knives, to experimenting (and failing) with PVA glues, and finally sealing everything with resin—this hands-on project shows every step, every disaster, and every glorious triumph. Whether you’re a Star Wars fanatic or just love epic prop-building adventures, you’ll see how to take a crazy idea and turn it into a display-worthy showpiece. Join me as I relive my missteps, share tips for avoiding them, and celebrate the thrill of bringing Han Solo’s iconic carbon freeze moment to life. May the foam (and resin!) be with you!

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Timecodes:

00:00 Intro
00:35 The beginning steps
01:00 The face
01:14 The frame
01:51 The body
05:00 The hands
06:00 Carbonite with resin
07:16 Grilled halloumi
07:59 Fixed and final steps
08:55 Final prop

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