Thanks to everyone here for threads and plans. they have been excellent and so thought I’d share my build.
It’s mostly made out of EVA foam and foamcore.
I 3D printed bits that would be either tricky to make or needed to be more solid.
Layout out the 3D Prints
Black stuff is EVA foam matting, White stuff is 5mm foamcore
and here it is primed. I coated everthing in PVA to seal the foam first and then rattlecan plastikote primer
matt black plastikote.. weathering with a silver sharpie and a tiny bit of drybrushing with some bolt gun metal, then onto stickers 
being in the UK alice frames aren’t that cheap to import so decided to make something similar. it’s 20mm conduit pipe and I designed and 3D printed some slot on brackets for the base. These were coated a few times in XTC3D for strength and then epoxied on some angled support bars.
I added a slight heat bend to the top section and then mounted it to the MDF motherboard using the conduit mounting brackets and some cable ties for extra strength.
once the straps were sprayed with a canvas spray olive green and attached it all looks ok IMO
I haven’t taken as many pics of the thrower with it being completely 3D printed, but here’s where I’m at so far.
the power on switch turns my pack lights on, but that’s all.
I’ve got some gear to add audio and a load more LED stuff, which I’ll sort when I get some more spare time.
managed to find some OK looking cheap overalls and with the name & no ghost patch and my black work boots I’m pretty happy with how it looks
