Cardboard Jedi Starfighter

Hello everybody ! In this Instructable, I'm going to show you how to make this variant of the Jedi Starfighters from Star Wars. This model is a blend of the original wedge shaped Delta 7 (as seen in Attack of the Clones) and the ETA-2 (as seen in Revenge of the Sith). It can be found as a display piece in Anakin Skywalker's quarters in Season 6 Episode 6 of the Star Wars: The Clone Wars Series (shown above). It's a simple cardboard display piece, but it's a fine addition to anyone's collection !

The design is my own, but I built the model with the assistance of tools available through the University of Massachusetts, Lowell (such as Solidworks access, micrometers and the laser cutter). To make this model perfectly, you will also need access to these sorts of tools, as the Starfighter is designed to hold itself together without glue or tape.

~ Two (2) 12 by 12 inch sheets of 0.15 inch corrugated cardboard (this dimension is required for the model to fit together well, with a tolerance of +0", -0.025"). Other thicknesses can be used, but dimensions on the slots and cuts would need to be adjusted accordingly to ensure a secure fit.

~ Access to a laser-cutter (any nearby makerspace should have this)

~ A set of calipers or micrometers to measure the thickness of cardboard

~ Dxf files attached

~ Patience !

Find applicable cardboard (0.125 - 0.15 inches thick). This number is important as this drives how all the tabs will fit together and how well the model supports its own weight. You will need two 12 by 12 inch sheets (preferably slightly larger to make sure all the parts fit).

Take this cardboard and the attached DXF files to a local makerspace with an available laser cutter. If you do not know how to run a laser cutter, there should be people available to help.

Each of the files needs to be scaled to the laser cutter. Layout1.DXF should be scaled so that the wings (Part 7 and 13, as labeled in Step 2) are each 9 inches long. Layout2.DXF should be scaled so that Part 16 (as labeled in Step 2) is 4.5 inches long.

After all the parts are cut, proceed to Step 2.

At this point, you have selected cardboard and cut the necessary pieces. You are now ready to start building the Starfighter ! As shown in the image above, start with Part 1.

Some notes pertaining to the rest of the model: all of the tabs will be delicate and some sections are very thin. However, the model is designed to keep itself together without glue or tape, which means the holes are smaller than the corresponding tabs. If something is not slipping together immediately, do not force the parts into place. As you will see in my images, I bent a few parts doing exactly that.

Insert the highlighted tabs of Part 2 into the highlighted holes of Part 1.

Slot the highlighted hole of Part 3 over the highlighted tabs of Part 2.

Grab Part 4. Delicately bend the 2 Part 3s outward and insert the highlighted tabs of Part 4 into the highlighted holes of Part 1. While releasing the Part 3s into their original position, make sure the thin strips sit in the side channels of Part 4.

Grab the other Part 2. Delicately bend the 2 Part 3s inward and slot the highlighted hole of Part 3 over the highlighted tabs of Part 2. While releasing the Part 3s into their original position, make sure the tabs and holes properly align.

Grab Parts 5 and 6. Slide the slot of Part 5 over the highlighted rectangular extension at the front of Part 1. The side channels of 5 should line up with Part 3.

Flip the frame around and fit 6 highlighted tabs of Part 6 into the 3 corresponding highlighted holes of Part 3. The frame is now complete.

Grab Parts 7 (1x), 8 (2x), 9 (1x) and 10 (1x). Follow the images above.

Insert the highlighted tabs of Part 8 into the slots of Part 7 so that the colors are properly aligned. Then shift Part 8 towards the back of the wing as diagramed. Repeat for both Part 8s. NOTE: Part 8 has some very thin sections, do not force the part into place, as something is likely to bend or break.

Flip the wing. Press Part 9 into the cut slots of both Part 8s. NOTE: Part 9 has a long end and a short end. Make sure the long end of Part 9 is facing towards the front of the wing, as shown here.

Grab Part 10 and slide it onto the back of both Part 8s. NOTE: The cutout of Part 10 is not a square. Rotate until it fits.

Connect the highlighted holes of Part 7 on the wing to the highlighted tabs on Part 2 of the frame.

This is a mirror of Step 8. Repeat Step 8 to build this wing.

Attach this wing to the same corresponding holes as shown in Step 9.

Grab Parts 11 (4x) and 12 (4x). Slot the highlighted section of Part 11 and the highlighted sections of Part 12 together as shown.

Attach the highlighted tab of Part 11 in the S Foil to the highlighted hole of Part 7 of the wing.

Grab Part 13. Connect the tabs from parts 2 and 11 to the highlighted holes of Part 13. Repeat on the other side.

Select both Part 15s.

NOTE: In some of these photos, Part 9 was already installed along the front sides of the wings. However, through further experimentation, I found that adding the wing brace works best before Part 9 is attached. Please disregard the pieces that have not yet been added in these instructions.

Gently pinch together the forward section of one wing. To insert Part 15, first direct one of the prongs into the slot at a 45 degree angle. As you push the prong through both wings, rotate the brace so that it becomes parallel with the wings. Then slide the brace forward so that it locks the wings together. Do the same for the other wing.

Grab Parts 9 and 14. Fit them into the appropriate places as shown in the diagram. Parts 9 fit into the open slots on the bow (front) and Parts 14 fit into the 3 slots towards the stern (back).

NOTE: Part 15 from the previous step is not visible in any of these photos because these photos were taken before I switched the steps around. In your model, the wing braces (part 15) should already be installed.

Grab Parts 16 and 17. Align the highlighted holes of Part 16 with the highlighted tabs of Parts 4, 5 and 6. Parts 17 should be aligned so that they lay directly adjacent to Part 16.

Grab Parts 18 and 19.

NOTE: The Part 18 included in the DXF file should look like the one provided in the image of Part 18 with the highlighted tabs (in this step). My version looks different because my initial cut was wrong, so I chose to cut off the highlighted tabs.

First, slot Part 19 into the upper slot of Part 18 to look like the provided images. Then take the orange highlighted tabs from Part 18 and insert them into the highlighted holes of Part 6 on the frame. Once the tabs are fully pushed into Part 6, push the canopy down so that the yellow highlighted holes on Part 18 attach to the highlighted holes of Part 16.

Grab Parts 21 and 22. Attach the orange highlighted slots from Part 21 and 22 together as shown in the image. Then attach the Astromech head to the Starfighter, following the highlighted tabs and slots on Parts 16, 21 and 22.

Congratulations, you have finished the model and have a replica of a Jedi Starfighter ! This can be flown around, suspended from the ceiling or simply set down on the bottom S Foils (as shown in the image). However, to build the accompanying stand continue onto Steps 20 - 21.

Grab Parts 23 and 24, which will be the two remaining parts. Slot the highlighted sections together; there is no correct orientation, as part 23 is symmetrical.

Orient the Starfighter so that Part 1 is visible. Align the highlighted tabs of the stand with the associated highlighted holes in Part 1. Make sure the slots in the stand slide over the 2 Part 2s. Now the model is complete.

You have finished the project ! I hope you enjoyed the build and liked how this turned out ! Please feel free to reach out with any questions.