No Death Star is complete without Blastdoors 🙂 These instructions will show you how to build this optional "add on" to your Death Star hallways and rooms.
The Blastdoors are designed in a grid system like LEGO. This allows you to place your door anywhere you want in your Death Star hallways and it will always line up with 5 panels.
Pausing the movie, I counted there are 7 layers in a Blastdoor. So you will need to cut out 7 identical 30cm x 15.5cm rectangles.
This is the thickness your Blastdoor will be and is exactly ONE wall unit thick which means you can place it anywhere you want in your hallway diorama.
The Blastdoor decals are too wide to fit on a 8.5"x11" sheet so I had to split it in two pieces. NOTE: If you just want a CLOSED blastdoors background, You just need to print and apply that decal to a 30cmx15.5cm foamcore rectangle and ignore all the layers and frame cutting
First place the left side of the Door decal onto your foamcore. Be careful, it's hard to peel off once attached. Gluestick will allow you to move it around more easy if you don't use full size decal sheets in your printer.
Now carefully place the Right Side Decal. Align your RIGHT edge first and then press it towards the center. It's ok if some overlaps a little as long as the frame lines meet properly.
You now have the outside skin on the FRONT OCTAGONAL FRAME piece. Since corners are tricky with a blade, thry this great idea... First do a rough cut of the inside in order to toss away the center of the foamcore rectangle.
Now get a hole puncher and place it along the curved edges of the Decal and punch away.
See how the punch creates rounded holes that match the decal angles. Much cleaner and easier than a blade.
Continue to make holes at each corner of your octagonal Blastdoor frame.
Now switch to a Xacto Pen (easier than a knife since the blade is pointy and precise) to connect the dots with a ruler and make a clean cut along the Decals edges.
You will now have a nice clean edge like this that ends with perfect rounded corners. Use your ruler and x-acto pen to cut the remaining edges.
After a few minutes, you will have connected all the dots and have your first perfectly clean Front Frame.
Here is a tease of what the door will look like when you place it in your hallway diorama. As you can see it already gives you the movie feel, but we are not done yet 🙂
Repeat the previous steps so that you build a SECOND Octagonal Frame which will become the REAR of your blastdoor.
Now for the inner frames. Take one of your Blastdoor octagonal frames and one 30cmx15.5cm foamcore rectangle.
Place the octagon rectangle on top, ALIGN with the outer edges and DO NOT GLUE. Just TRACE all the way around the inside edges with a pencil.
Remove the frame and extend each of your pencil lines until the corners meet and create a perfect rectangle frame
Use a x-acto pen or knife to cut out along the outside lines giving you a picture frame rectangle with 90 degree corners. Repeat trace and cut to make 2 pieces.
Time to create the DOUBLE THICKNESS of the layers. Take a Blastdoor octagonal frame and another 30cm x 15.5 cm rectangles.
Align the 2 pieces outer edges and this time, Hot Glue the 2 layers together. Repeat again to make the back frame.
Now grab a 90 degree corners frame and a 30cm x 15.5cm rectangle piece.
just as you did with the Octagonal Front Frames, Align the edges and Hot Glue the 2 pieces together. Repeat again to obtain 2 similar pieces.
You should now have 4 DOUBLE THICKNESS Blastdoor pieces. 2 Outer SKIN Octagonal frames and 2 90 degree angle frames.
Take your Xacto Pen or Knife and carefully (NEW blades make smoother edges) follow the top piece layer as your guide. For the rounded corners, you might want to switch to the X-acto PEN with the pointy triangle blades. Watch your fingers !!!
After several minutes, you now have your 2 FRONT and BACK Octagon Frame pieces completed. Put those aside for now.
Now do the same procedure with your regular 90 degree corner frames. These are a little easier since there are no round edges.
Poke out the center foamcore after you cut all around. You should now have a 2 layer thick 90 degree corner middle frame. Repeat to cut your other middle frame.
All your cuts are now done, you should have 4 double thick frames...
2 (front and back) with skin decals and 2 regular 90 degree corner middle frames. Time for Doritos 😛
No these aren't really Doritos 🙂 I cut 3 identical 6.5cm x 6.5cm black foamcore squares and then cut them diagonally in half to create 6 identical triangles.
Print my Blast Doors Corner decal (I like to use full size label sheets that you just peel and apply. No messy glue)
Cut each square along the edges and the red guide lines.
Now peel one decal (Use gluestick if you don't have label sheets) and align the center of the Decal with the LONG edge of the Door corner.
Bend the decal from the edge towards each sides corner tip and press down to remove bubbles or folds on the corners.
Don't worry if the door corner decal doesn't fit perfectly inside the triangle. We will fix that in the next step.
All you need to do now is get your ruler and Xacto Pen/knife and slice off the excess on each side.
You now have a perfect looking Dorito 🙂
Repeat the same process for the remaining 5 door corners.
You will also need 6 little scraps of foamcore about 1 cm wide to level the frames.
Time to assemble the Blastdoor. Start with the FRONT OCTAGONAL frame and flip it face down on the table.
Take 2 Triangles and Hot Glue them to opposite corners with the long edge facing the insides of the frame (Remember to flip the frame on the backside. you don't want to stick the triangles onto the decals) Take 2 scrap pieces and Hot Glue those on the remaining 2 corners.
Now grab a middle 90 degree corner frame, align it with the outside edges and Hot Glue it to the Triangles and scrap pieces. NOTE: Make sure frames are NOT UPSIDE DOWN to one another. Top is thicker and bottom is the thin border.
The Dorito corners simulate an open door along it's track. It is NORMAL for the center of frames to NOT TOUCH each other. You want that track GAP effect where the door slides along when opening and closing like in the movie.
Ok so we are ready for another layer of door corners...
Grab 2 more triangles and Hot Glue them on top of the frame BUT IMPORTANT : at opposite corners from the last time. Also Hot Glue 2 scraps on the remaining corners.
Now time for the 2nd middle 90 degree corner frame. Align it carefully with the outer edges of the previous 2 pieces and Hot Glue in place onto the Triangle and scrap pieces. REMEMBER to MAKE SURE to have the thinner bottom match with the other 2.
Time for the last 2 Doritos 🙂 Align and Hot Glue the 2 triangles, this time on the SAME corners as the FIRST TIME.
You want the outer triangles to be located in the same corners (like bottom in this photo) and the middle triangle layer in the opposite corner (seen on top here in the photo)
Finaly, grab your back octagonal frame and sandwich all the layers together. Make sure to ALIGN the outer edges AND make sure the thin edge matches the other 3 thin sides. It's that easy, just takes a little time that's all.
Your Blast Door is completed . What do you think? does it look like the movie? It makes me smile when I look at it 🙂
One last option you can add if you are displaying the door sideways like in the next photo, Who wants to see layers of foamcore 🙂 Just print a basic wall decal of your choice and apply or glue it along the outer side of your door.
And there you have it. This is what it looks like when the Blastdoor is placed separating your main hallway and fits perfectly within the 1 grid width of any Main Wall. Can you picture Han jumping through ? 🙂
You can also choose to use the Blastdoor facing forwards like a window to add depth to your basic hallway. Picture Darth vs Ben on the other side 🙂
Created February 2005 X
Welcome to the Death Star LARGE BLASTDOOR step by step MAKING OF page. These instructions will help you build my diorama so that you can display your own action figures at home just like the ones you see here in the GALLERY section. In some cases there is also VIDEO MAKING OF for those who find still images a little more confusing. You can see if one is available for this diorama in the Tutorial SPEED INDEX page. While you are there, you can also see what DECALS, BLUEPRINTS, MATERIALS LIST is available as well. Not all Dioramas instructions have or need ALL 5 Tutorials categories, especially older NiubNiub era scenes. I do plan on going back at some point to revisit, rebuild these older fan favourite scenes and create the missing content. X
If there is ONE TRUE ICONIC set design in the Star Wars universe, it has to be the DEATH STAR. The simplicity of the design is what makes it’s hallways the coolest hallways in cinema history 🙂 X
The blastdoors, like the main hallway panels, arches, curved walls and doors were all designed to interlock like when you build LEGO. All pieces fit a grid system that allows you to connect your Blastdoor to hallways that lead to rooms like Red Control Room, Docking Bay, Trash Compactor to name a few (all available as separate instructions in the TUTORIALS Menu) The sky is the limit and the perfect background display for your Hasbro figures. X
Did you already build this Diorama ? At home or at our Star Wars Celebration Diorama Builders workshop ? Would you like to show it in the site’s GALLERY VISITORS DIORAMAS section, YES ? That is Awesome !!! You can find out all the details on how to email me your photos on the VISITORS SUBMISSIONS INFO page … When I get your photos, I will create your very own page just like this one. You may not realize it but work does inspire others to join in the fun of making Action Figure Dioramas. X
If you attended one of our Star Wars Celebration Diorama Builders workshops and have a Facebook account, why not JOIN the OFFICIAL DIORAMA BUILDERS FAN CLUB group today !! X Catch up with fellow visitors and exchange stories, read cool interviews with the crew, exchange photos, fun surprises and grab some FAN ONLY merchandise next year at actual future conventions 🙂 X