D-42 shell build (PIC Intensive)

[D-42]

So I’ve been bored since Halloween and decided I’d make up a few more packs using mostly the additional parts I had laying around from my first build. I’ll have close to enough to build one full pack and two partials but this also gave me a good chance to document the entire build in one thread with new pictures.

You can find all my pictures here http://picasaweb.google.com/bill.warner/MultiBuildDocs#

So first off I had to pull the parts. This is fresh off the vac table:

Using these I wanted to clean up the webbing that showed up. I used some different nippers and diagonal cutters to cut everything flush:

Then I sanded it all flush and clean so that paint will hide the rest of it nicely Sometimes you may want to fill in any gaps that come from this. You can easily do this with either bondo or JB Weld depending on the size.

Then ruff cut everything out:

Then trim it all to size with some tin snips:

On the part that glues together I trim up a little higher. It gets rather thin in this spot but turns out ok when glued to the bottom half.

then size everything up, and glue it together with ABS glue:

I then rub down all the ABS with a paper towel dampened with Goof-Off. This helps paint to stick much better.

[D-42]

So then I used some of the PVC that I had around and cut them to length and ABS glued some ABS squares to the end of them:

Then rounded the ends once the ABS glue was dry

Similar for the HGA:

Then for the N-Filter using two of the PVC Couplers glued together then capped in the same fashion:

Played around with a weld look. Not 100% happy with it so far, may add some hot glue to it to add a little build up.

Then I cut them to length, marked and drilled the holes.

Also cut the boosters out and had 3 ready to go:

[D-42]

For the tube that goes above the clippard, i didn’t really do the vac mold 100% right here or it’d be easy to hotglue in with high temp hot glue, so for this one I actually use a dowel plug and screw:

The injectors are from the sink isle at home depot:

Using my hole saw again:

Also trimmed out the required holds for lighting:

This is as far as I have gotten up until now. More updates will come as progress is made.

[sbonse]

I will be following this thread really close as im currently building a pack using one of your vacformed shells that i got off you on ebay.

Im using fairly similar materials as you are for the parts.

here is a link to my build.

http://www.gbfans.com/community/viewtopic.php?f=2&t=22634

The vacformed shell is a really nice place to start and cheap compared to the resin shells.

[nick-a-tron]

Great looking build!

[Sebastian_Arms]

Very nice. Giving some props to the vacuumform packs out there.

Cheers

Sebastian

[D-42]

Another update time:

Working on the injectors:

Hot glued together

[D-42]

Here is my clam shell vac formed ION Arm:

Hot glue for the weld lines, just needs some paint now.

[D-42]

The Nfilter attachment again with some 3/4 drywall screws.

Went back to hotglue welds. They just seem to look more like a weld. I wait for the glue to dry then swirl it with the tip of the hot glue gun a little.

[sbonse]

Pack is looking good. never even thought of using a glue gun to produce the welds.

[D-42]

This was my first prop that I used the hot glue for a weld lookalike. The first time I’d seen it someone was making a quick stage prop and used hot glue and paint and I thought wow that was good results forsomething so obvious and easy.

This was for halloween last year. ended up just using it to point out chicks with nice racks, calling them “Busted”

was a great time.

[D-42]

Bumper

Filer Tubes

ION Arm attachment

[Letmebleed75]

Beautiful work. never thought a vacuumformed shell would look so great

[D-42]

Sorry I haven’t updated in a while, been busy getting shells for people and work. stupid 16hour day yesterday.

[gb_dan-1]

@Letmebleed75

Beautiful work. never thought a vacuumformed shell would look so great

Vac’d shells can become BEAUTIFUL packs! Here is the last vac pack I made back in 2005 using a Javamonkey upper module and my own vac’d spacer.


Looking great so far D-42!! Keep up the good work!

[D-42]

So, haven’t done much work on the pack, but I wanted to try to get one of my vac shelled throwers together. Here is the start of that project:

Should make for an easy base to add electronics and light kits too.

[D-42]

So, in a shed in my friends back yard, with boxes marked tools, dishes, toys, etc… there is a lone box marked “portable particle accelerator x3” After losing out on the first house, second house, third house, second house again, we are now on our fourth house. Luckly this one requires little more than some paint to be ready to move in, and includeds a nice ~1000 square foot shop. It’s in short sale right now so we are looking at 2-6 months before move in.

I hate not having my tools readily available and my projects packed up.

[TheWug]

Does anyone know if this will work with a mmm motherboard?

[D-42]

As long as it is made to spec with stefan’s plans or at least very close.

[tk-fett]

Any updates on this pack?