Curious if there is anything out there that describes how they made the life size figure of Han in Carbonite.
Was it a full body cast, if so how did they get the clothes, or was it an artistic sculpture?
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It was a cast (as was Mark Hamil's hand getting cut off). I haven't found any interviews but this tweet says it took 20 mins to make the face as shown
Fun fact: only Harrison's face was cast. They used a body double for the rest (was the same actor who played Bossk the bounty hunter).
Q: You were the body double for Han Solo in carbonite. How did this came to be?
A: Irvin Kershner had the idea. We were in the props room where they put a shroud over me and two drinking straws through my nose so I could breath. They later cut my face out and put Harrison Ford’s in. Irvin Kershner and I looked at the finished product on the set and Harrison came over. He said he was thinking of turning one of these into a coffee table. I don’t know if he ever did.