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Adam Savage Compares Han Solo DL-44 Blaster Builds!
⏱ 19 min video · 3 min read19 Jun 2026Worth watching
TL;DR
Adam Savage and Don Bies compare their Han Solo DL-44 blaster builds, but the conversation quickly expands into fascinating behind-the-scenes stories about Star Wars prop-making, R2-D2 construction secrets, ILM culture, and the evolving role of fandom within professional film production.
Key points
1
The DL-44 blaster is based on a Mauser pistol — the exact same gun used in a Frank Sinatra film, which was then modified with extra parts for the Star Wars prop.
2
Don Bies built his DL-44 replica about four to five years ago using a Dennis resin kit base with parts sourced from Blasttec, and heavily weathered it to feel screen-accurate.
3
The R2-D2 units in the prequel trilogy are largely the original brazed-aluminum R2s from the classic films — no two units share identical measurements, making blueprinting impossible.
4
Don Bies defied George Lucas and VFX supervisors to ensure Vader's helmet in Revenge of the Sith split correctly (matching Return of the Jedi), backing it up with reference photos.
5
ILM in its early days required crew to hide their Star Wars fandom, but the industry has since shifted — FBFX hired a cosplayer who had already built a dozen clone trooper suits to make the official costume.
Key takeaways
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For prop weathering, the UK crew used a mixture of beeswax, kerosene, and Fuller's earth as removable dirt, though kerosene risks attacking paint underneath — acrylic paint washed with alcohol is a safer alternative.
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For episode-to-episode R2-D2 costume changes on the prequels, the crew switched from painting to vinyl stickers so dressing could be easily swapped between units without repainting.
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When building screen-accurate replicas, embrace imperfection — the original R2-D2 aluminum parts were cut with nibblers leaving uneven edges, and that hand-made crappiness is what makes them look right on screen.
Notable quotes
“I said, I wasnt going to do it. No matter what they would tell me, I would have still done it the right way.”
“It wasnt until many years later that things became much more precious than they actually were.”
“I can not see it. Like I couldnt tell you anything about what it looks like after Ive watched it in this movie because its too complex and it doesnt give me a hamburger-like silhouette like the Falcon.”
Worth watching?
✅
Worth watching the full video?
Watch if you are a Star Wars prop or filmmaking fan — the Vader helmet and R2-D2 stories alone are worth it, but the full conversation has a relaxed, insider depth that the summary cannot fully replicate.
Saved you some time? The creator still deserves a like.
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