When I was a kid watching Star Wars for the first time, like so many others I was awed by the scope and scale of the planets and technology in that galaxy far, far away. The worlds were both primal and futuristic, and I was instantly fascinated. I’ll never forget my awe at the scene of the Millennium Falcon getting caught in the Death Star’s tractor beam and the sense of scale the visuals accomplished when the ship gets pulled into the massive battle station’s docking bay. As a kid intrigued by the structure of things, I was blown away.
Now, after training as an architect and over 20 years in the cast concrete business, it’s with great pleasure and reverence that I get to make my very own concrete Death Star — and hold something that has always been in my mind such a massive and impressive entity right in the palm of my hand.
Using Death Star ice molds and a few tools and materials from the hardware store, you too can make your own fully armed and operational concrete battle station. Kids — please be safe and get an adult to help! Now let’s begin!
Most items can be purchased at a hardware store like Home Depot.
- Death Star ice mold (available at ThinkGeek.com)
- Concrete mix (we recommend “Rapid Set Cement All”)
- Mold release spray
- Small mixing bucket
- Mixing tool — drill with attachment or mix by hand with a metal shovel or trowel
- Smaller container to pour
- Dust mask
- Protective eyewear
1. Spray mold release on the inside of the Death Star mold.
2. Align notches on mold and place together, secure with tape.
3. Wearing gloves, protective eyewear, and a dust mask, follow the directions on the box, put the cement in the bucket, and add water gradually to reach the desired consistency. Mix until fully blended and easy to pour.
4. Put the mix into a smaller container for easier pouring.
5. Hold the funnel over the opening on the top of the mold and slowly pour the mix in.
6. When the mold is full, place a finger securely over the opening and gently shake the mold to remove bubbles. Do not shake vigorously — this will create more bubbles.
7. Place back on the table and pour more mix to fill the mold to the top. Gently tap exterior to minimize bubbles.
8. Leave overnight to dry.
9. Remove tape and carefully pull the mold apart.
10. Gently chip off any excess concrete around the seam.
11. Sand the base to remove any excess concrete from the mold opening and to create an area that will sit flat.
12. Enjoy your indestructible concrete Death Star. May the Force be with you!
With a background in architecture, Mark Rogero decided to pursue the path of architectural cast concrete, founding Concreteworks in a small artist warehouse in 1991. His work in cast concrete spans from traditional countertops and bars to innovative furniture utilizing the latest cutting edge technology.