I think I’ve made enough progress that it is good from me to share now. Over the last month I have been working on a set of proton packs for me and my friends for halloween 2009. I started out building a master mold from Balsa, a cake pan, and washers. I then made a silicon mold with a fiberglass support shell, and I am now in the proccess of pulling fiberglass shells. (one is currently on ebay). Here are some progress pictures.
Looking good so far! Can’t wait to see the end result.
From the color it appears you are casting parts with polyester resin, word of advise don’t it will become brittle with age and explode on impact or stress…
Hmmmm…
Gonna make the gun box a 2 part mold? Not sure how making the pack shells in 2 parts will work.
Interesting stuff tho.
making the pack shell two parts is nothing new. The main reason I did that is to create a smooth surface where they connect, which would have been impossible to sand if the master was one piece.
Worse case I can always glue the two halves together now.
As far as the resin cast, they are not load bearing and if they were impacted hard enough to break I think the pack would have bigger problems.
Here are some more pictures. The shell in the mold is my “seal of approval” mold which I am keeping. The one that shows you how they turned out was my first attempt, but besides minor weak points came out pretty good IMHO.
wow…talk about clean up…
pictures like that are the reason i have nightmares about fiberglass molds…
not that there’s anything wrong with them…
they are on ebay now i think
Sal
I am getting some wierd reactions here. I was expecting some positive feed back I guess.
The shell needs to be trimmed. This will take about 2 min with a dremmel. I just finished laying up personal pack 3, and yes one is currently on ebay. This weekend I will post some picutes of how these packs clean up.
sorry if it sounded negative, wasn’t my intention. The shell looks great, and i wish i had the knowdlege to do one like that! Great work, i can’t wait to see it painted!!! 
Props to you Wayne for giving it a go and doing it yourself, after all you are the only one here who needs to be happy with it. Keep up the good work, i’m sure the end result will look great.
i wasnt trying to be negative…just looks like a lot of work :!:
gratz on the build and keep us updated
Nice man,can’t wait to see it finished.
i didn’t mean to come off negative either. i got mad respect for anybody with big enough ■■■■■ to try fiberglass…it scares the be-jesus out of me!!!
Anymore updates to this?
Little impatient aren’t we? Anyway, here you go:
They look good but I’d have to say, you are missing a section of cosmetic plating that is about a 1/2" thick on the left side of the pack.
If you look at this page on stefan’s plans:
http://www.gbfans.com/image.php?url=/images/equipment/plans/stefan_10.jpg
You can see the one filler plug is mounted on it. It would also provide support when connecting your top and bottom halves of your mold. Other then that, these look pretty good man, keep it up!
Heh yea I’m always impatient,looking good though man.
I think he’s probably going to include that on his motherboard to help link everything together (at least thats what I would be inclined to do)
@ DJ1500 …I’m assuming you will be using wood mobos cut to the outside dimensions of your shells?
Looks good