Star Wars Millennium Falcon Light Switch Cover

I originally put this up on Thingiverse here.

Summary

Version 2 is live! My initial version had a few issues, primarily the tolerances on the holes for the switch and the screws were a little too tight. V2 fixes that by expanding all holes by about 1/64" in every direction. I also took off the remnants of the top gun that were leftover from my source model, since most of the gun was cut out by the switch hole anyways.

This was inspired by the "STAR WARS Millennium Falcon Millennium Falcon Light Switch Cover" by colinmccheese. I attempted to fix a few issues I had with that print, particularly with the alignment of the bottom screw hole.

If the tolerances are too tight for the screw holes, use a 9/64" drill bit to clean them up. It might also be necessary to shave off some imperfections from the switch hole with a razor blade in order for the switch to fit through.

How I Designed This

Initial Design

I designed this in SketchUp because that's what I'm most proficient with. Although I took inspiration from colinmccheese's design, I started my design from scratch within SketchUp. The base plate is just a box with a chamfer I made using the "Follow Me" tool. The model of the Falcon is adapted from the Millennium Falcon model by Ian W. in the SketchUp 3D Warehouse. I got the best results when all of the pieces in the model were a solid, but I had issues with combining the different pieces into a single solid. I've included the latest SketchUp file I made which consists of five solids. Whenever I tried to combine any of these into a single solid the resulting object was not seen as a solid by SketchUp and this caused issues when I exported it and tried to slice it. I've also included a second SketchUp file in which all of the components are individual solids before I started combining them. This version is more easily customized within SketchUp. It also has a more detailed and realistic satellite dish, and lacks the chamfer for recessing the screws.

V2 Design.

To make the second iteration I imported my sketchup file into fusion 360 and converted the mesh to a solid. Then I used the solid tools to enlarge the holes and fix some of the other errors from the initial design. I've included the Fusion 360 file in my files so others can more easily edit my design.