I’m about finished building my 2nd Proton Pack. My 1st one was a quick, scratch build. This one is much more detailed and sturdy, as I want it to look great and last a long time. I also need it to be practical in every way possible, since it will be used at a LOT of events. One problem facing busters who wear Packs regularly is changing or charging batteries which power Pack lights. I prefer to use AA cells of either the disposable or rechargeable variety for convenience. I don’t want to build a charger into my Pack (because I’ll forget to charge my batteries :walterpeck: ), and I really don’t ever want to open it to change batteries… but I refuse to have my batteries outside the Pack body. So, I devised the solution described below.
I needed to find a location where I could hide batteries AND get access to them without having to pull the Pack open or install a trap door. The Booster Tube seemed like a perfect location.
This looks like a normal Booster Tube assembly, right? Well, it is… sort of. The body is standard black plastic pipe, and the Plug is a resin-cast piece. I’ve got 2 threaded studs through the back, so I can bolt it to my Pack, too.
BOOM! Battery holder inside!
Here’s a look inside. I made a ledge where the Plug can rest by cutting another length of black pipe, removing a lengthwise section out of it, and squeezing it inside. The inner pipe is held in place by the studs I drilled and threaded through the inner and outer pieces together.
Here’s a look at the battery holder. It holds 8 AA batteries, but R2Devo’s kit only requires 9v, so I jumped over 2 cells. The holder was purchased at Radio Shack and is held in place on the Plug with Gorilla Glue only.
Here’s a look up from the bottom end of the Tube. You can see that the battery holder fits right inside the inner pipe. It’s not slip fit, but it doesn’t allow much wiggle room.
On the Pack, I drilled a 1/2" hole through the shell where I can feed the battery lead from the light kit into the Booster Tube.
Here’s a look from the inside of the Pack with the Booster Tube installed. Eazy Peazy.
The great thing is that I can use rechargeable AA batteries, disposable AA batteries, or even gut a 9.6v RC car Pack and fit the cells into this kind of holder for more juice.
I’m also considering getting another Tube Plug and battery holder that I can keep loaded up with batteries, so I can just swap the assembly when I need a fresh set.
I don’t have sound yet, so, this solution may not power both lights and sound, but it works great for now.
Also, if I find that the assembly rattles around at all, it wouldn’t be any problem to wrap thin foam around the butt of the battery holder or put adhesive rubber bumpers on it for a more snug fit inside the Tube.
