I was kinda thinking about the car itself being it.

Either way would actually work tho.

Here's a small HiC mold. It's only $10!

http://www.thinkgeek.com/product/e845/?srp=1

I saw one like it, but its just a little too small. The PWD car is almost 7in long and the mold is about 3.5in. If I ...

My son is in Cub Scouts and for next years Pinewood Derby, we'd like to make a HIC car.
I'm looking to see if anyone would be able to make the Han pieces that would fit on something that size. It would have to be shorter than 7" and no more than 2 3/4" wide.

Any ideas or would someone be able to ...

Lot of great resources out there. There are some talented folks on the site here that could probably help you out. If you're looking at sewing your own (I have no skills) then definately check out the Imperial Officer boards.

The base pattern will be a modified Mccall's 4745 costume. Do a search ...

Looks good!