# drjameshouse's GB1 Proton Back Build \*\*Now Textured!\*\* **URL:** \ **Category:** Proton Packs\ **Created:** [April 23, 2014, 5:54pm UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707 "2014-04-23T17:54:03Z")\ **Posts on this page:** 20\ **Page:** 1
**Author:** ![drjameshouse](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/d/6a8cbe/32.png) [@drjameshouse](https://forum.gbfans.com/u/drjameshouse)\ **Post date:** [April 23, 2014, 5:54pm UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/1 "2014-04-23T17:54:03Z")
So this has been a long time coming, and I was on the fence about actually starting a build thread since there are so many already. In the end I decided why not, maybe I can get some pointers along the way. I’ve collecting parts for over 2 years now. Life and other projects always seemed to get in the way of starting a build. Now I have finally gotten some time and almost all the parts needed to make it happen. Currently I don’t have a particular pack that I will be imitating. That may change along the way, we’ll see. I’ll try to outline what/who’s parts I’ll be using, but if I miss some and you want to know, just ask I’ll share the details. First let’s start out by showing the workspace: [![image](http://www.gbfans.com/images/pb/drjameshouse/Proton Packs\_GB1 Pack\_Shop\_zps8cd4735b.jpg)](http://s1190.photobucket.com/user/drjameshouse/media/Proton%20Packs/GB1%20Pack/Shop_zps8cd4735b.jpg.html) It’s insulated heavily, and I put in an older furnace and A/C from my mother’s house when she upgraded. So I shouldn’t have any issues with weather stopping progress. Next is my trusty assistant Bo: [![image](http://www.gbfans.com/images/pb/drjameshouse/Proton Packs\_GB1 Pack\_8b061b49-7cf2-42f6-99d0-239c6e3df1b9\_zpsf3a42a51.jpg)](http://s1190.photobucket.com/user/drjameshouse/media/Proton%20Packs/GB1%20Pack/8b061b49-7cf2-42f6-99d0-239c6e3df1b9_zpsf3a42a51.jpg.html) He isn’t very good at actually performing any work, but he is really cheap labor. And here is my collection of parts: [![image](http://www.gbfans.com/images/pb/drjameshouse/Proton Packs\_GB1 Pack\_IMG\_09401\_zps17213e26.jpg)](http://s1190.photobucket.com/user/drjameshouse/media/Proton%20Packs/GB1%20Pack/IMG_09401_zps17213e26.jpg.html) [![image](http://www.gbfans.com/images/pb/drjameshouse/Proton Packs\_GB1 Pack\_IMG\_09411\_zps5120e880.jpg)](http://s1190.photobucket.com/user/drjameshouse/media/Proton%20Packs/GB1%20Pack/IMG_09411_zps5120e880.jpg.html) It includes almost enough parts for 2 entire packs. Some items I have enough for at least 4 packs, so expect more builds in the future. I have also been able to collect about 10 alice frames (4 LC2’s and 6 LC1’s). After unboxing one of my bigi330 shells casted by Vince himself, I gave it a nice long bath. Sorry no pictures of that, since it was WAY to personal and revealing to post on the internet :lol: After drying it off I noticed that the shell didn’t sit flat all the way around. Here are a issue areas: [![image](http://www.gbfans.com/images/pb/drjameshouse/Proton Packs\_GB1 Pack\_IMG\_09451\_zps94f6a138.jpg)](http://s1190.photobucket.com/user/drjameshouse/media/Proton%20Packs/GB1%20Pack/IMG_09451_zps94f6a138.jpg.html) [![image](http://www.gbfans.com/images/pb/drjameshouse/Proton Packs\_GB1 Pack\_IMG\_09441\_zps866c18d2.jpg)](http://s1190.photobucket.com/user/drjameshouse/media/Proton%20Packs/GB1%20Pack/IMG_09441_zps866c18d2.jpg.html) So I taped some sandpaper sheets down to the work table and sanded it as best I could making sure not to sand too much. [![image](http://www.gbfans.com/images/pb/drjameshouse/Proton Packs\_GB1 Pack\_IMG\_09461\_zps89c2b2e2.jpg)](http://s1190.photobucket.com/user/drjameshouse/media/Proton%20Packs/GB1%20Pack/IMG_09461_zps89c2b2e2.jpg.html) This took care of most of the problem areas, but there was still one spot that needed to be built up. I also noticed a few spots that were a little too thin for my tastes. So I built up some areas with fiberglass and other areas with epoxy putty, and sanded where necessary. [![image](http://www.gbfans.com/images/pb/drjameshouse/Proton Packs\_GB1 Pack\_IMG\_09511\_zps3964bc0f.jpg)](http://s1190.photobucket.com/user/drjameshouse/media/Proton%20Packs/GB1%20Pack/IMG_09511_zps3964bc0f.jpg.html) [![image](http://www.gbfans.com/images/pb/drjameshouse/Proton Packs\_GB1 Pack\_IMG\_09491\_zps1f239e62.jpg)](http://s1190.photobucket.com/user/drjameshouse/media/Proton%20Packs/GB1%20Pack/IMG_09491_zps1f239e62.jpg.html) After that was finished I cut off the eda discs with a dremel and sanded the area flat. [![image](http://www.gbfans.com/images/pb/drjameshouse/Proton Packs\_GB1 Pack\_IMG\_09611\_zpsc19facc8.jpg)](http://s1190.photobucket.com/user/drjameshouse/media/Proton%20Packs/GB1%20Pack/IMG_09611_zpsc19facc8.jpg.html) I cleaned up the metal eda discs I got from Vince’s metal parts bundle and drilled the holes in the discs and eda. The rivets I was going to use weren’t long enough as the fiberglass under the eda was pretty thick. I sanded/gound down the area (on the inside of the shell) so the rivets would work and then attached the metal eda discs. [![image](http://www.gbfans.com/images/pb/drjameshouse/Proton Packs\_GB1 Pack\_IMG\_09621\_zpsdf9a667f.jpg)](http://s1190.photobucket.com/user/drjameshouse/media/Proton%20Packs/GB1%20Pack/IMG_09621_zpsdf9a667f.jpg.html) Since they are made up of 2 1/8" stacked discs I will probably use a little filler to the seam, and also the rivet head. Next up will be cutting the [N-Filter](https://www.gbfans.com/wiki/equipment/proton-pack/n-filter) off and replacing it with the metal one… ---
**Author:** ![thebigone2087](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/t/d6d6ee/32.png) [@thebigone2087](https://forum.gbfans.com/u/thebigone2087)\ **Post date:** [April 23, 2014, 7:51pm UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/2 "2014-04-23T19:51:37Z")
Looking good. I think this is going to end up being pretty awesome. Are you going “hero” with aluminum attachments? ---
**Author:** ![THEbryon](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/t/c4cdca/32.png) [@THEbryon](https://forum.gbfans.com/u/THEbryon)\ **Post date:** [April 23, 2014, 8:07pm UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/3 "2014-04-23T20:07:01Z")
So you’re the reason I can’t find a decent LC-1. 😉 ---
**Author:** ![kurisu7885](https://forum.gbfans.com/user_avatar/forum.gbfans.com/kurisu7885/32/6555_2.png) [@kurisu7885](https://forum.gbfans.com/u/kurisu7885)\ **Post date:** [April 23, 2014, 8:48pm UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/4 "2014-04-23T20:48:26Z")
What was the reason for soaking the pack shell? ---
**Author:** ![THEbryon](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/t/c4cdca/32.png) [@THEbryon](https://forum.gbfans.com/u/THEbryon)\ **Post date:** [April 23, 2014, 9:14pm UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/5 "2014-04-23T21:14:31Z")
It’s advisable to wash the shell with warm soapy water to remove the mold release that is used. If you don’t, you stand a very good chance of your paint not sticking to the shell. ---
**Author:** ![kurisu7885](https://forum.gbfans.com/user_avatar/forum.gbfans.com/kurisu7885/32/6555_2.png) [@kurisu7885](https://forum.gbfans.com/u/kurisu7885)\ **Post date:** [April 23, 2014, 9:16pm UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/6 "2014-04-23T21:16:16Z")
> [@THEbryon](#): > > It’s advisable to wash the shell with warm soapy water to remove the mold release that is used. If you don’t, you stand a very good chance of your paint not sticking to the shell. Ah, ok, so at least a wipe down is a good idea. ---
**Author:** ![PssdffJay](https://forum.gbfans.com/user_avatar/forum.gbfans.com/pssdffjay/32/6529_2.png) [@PssdffJay](https://forum.gbfans.com/u/PssdffJay)\ **Post date:** [April 23, 2014, 10:55pm UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/7 "2014-04-23T22:55:11Z")
> [@THEbryon](#): > > So you’re the reason I can’t find a decent LC-1. 😉 I was going to comment on the number of frames you have. Somewhere there is an army surplus store with some empty shelves. ---
**Author:** ![drjameshouse](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/d/6a8cbe/32.png) [@drjameshouse](https://forum.gbfans.com/u/drjameshouse)\ **Post date:** [April 23, 2014, 11:45pm UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/8 "2014-04-23T23:45:40Z")
> [@thebigone2087](#): > > Looking good. I think this is going to end up being pretty awesome. Are you going “hero” with aluminum attachments? Yup. I’ll be doing all aluminum including the thrower. More to come on that later… > [@THEbryon](#): > > So you’re the reason I can’t find a decent LC-1. 😉 Only partially 😉 It took me a long while to piece them all together. Some from ebay and some from digging through surplus store that were 100+ miles away. In fact the only 100% complete one I found I paid way too much money for…but it is actually also the nicest. The LC2 frames (with correct padding) I found on craigslist. 4 of them for $20…not too bad. > [@kurisu7885](#): > > What was the reason for soaking the pack shell? As THEbryon said, it is to remove any residual mold release or grease to ensure texture/paint will stick. ---
**Author:** ![kingpin](https://forum.gbfans.com/user_avatar/forum.gbfans.com/kingpin/32/187259_2.png) [@kingpin](https://forum.gbfans.com/u/kingpin)\ **Post date:** [April 23, 2014, 11:55pm UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/9 "2014-04-23T23:55:35Z")
Off to a good start… and quite the ingenious method for sorting out the spots that didn’t lie flat. 🙂 Bo is absolutely adorable. I love Collies. 🙂 ---
**Author:** ![drjameshouse](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/d/6a8cbe/32.png) [@drjameshouse](https://forum.gbfans.com/u/drjameshouse)\ **Post date:** [April 25, 2014, 3:00am UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/10 "2014-04-25T03:00:15Z")
> [@Kingpin](#): > > Bo is absolutely adorable. I love Collies. He’s actually an Australian Shepard. Same family as Collies 😉 Ok, small update time. Yesterday I spent some time cleaning up the powercell window. Some of the cuts weren’t square and the window needed to be lengthened a tad. Results of that: There is a small area on the outside that needs a bit of filler, but I’ll get that after I’m done hacking things up and touch up the entire shell at once. Also here is another area that I reinforced: Then came the daunting task of replacing the cast [n-filter](https://www.gbfans.com/wiki/equipment/proton-pack/n-filter) with this: And it’s a good thing I’m doing it otherwise I might not have noticed this hole: After a bit of cutting and grinding I ended up like this: Setting the metal replacement in doesn’t look TOO bad: After taking a small break to rescue my assistant Bo from all the fly’s that were bothering him (what is it about Iowa that attracts so many damn fly’s? Maybe it’s the pigs…) I started to analyze how to attach the metal one. Obviously the real shells didn’t have a giant hole where the n-filter was to go and I didn’t feel comfortable just using epoxy putty where the edges of the shell met the filter. I just could envision a good wack into a door frame might knock it off. So after talking with a few friends off-site I decided if I was going to do something, I might as well over do it. So came building up an inner wall of fiberglass. I decided on this for two reasons. 1) It gave more surface area to epoxy glue it, and 2) It would allow me to easily use rivets or screws. So I started off by cutting some card stock and taping it around the N-Filter, making sure that the filter was square: I then fiberglassed on the inside of the shell against the card stock. The end result looks something like this: I then took a look at the [cyclotron](https://www.gbfans.com/wiki/equipment/proton-pack/cyclotron) holes. I analyzed some reference photos and came up with what I think is the thickness of the holes. I then made a jig or plug that is that height that I can put in each hole from the outside, and using an angle grinder with sanding disc, sand each to the appropriate thickness. It also came in handy when I accidentally sanded too much off while cleaning up my n-filter wall. I coated it with some petroleum jelly, put it in the hole, and filled the area back up with resin: If hoot see’s that last bit I’m sure there this will turn ‘R’ rated really fast. Well that’s all the progress so far. I am currently looking at the appropriate uneven hole spacing of the n-filter and going to draw up a template that hopefully comes close to what can be seen on the minnesota pack. If someone has a template for the uneven hole spacing already and wants to save me the trouble feel free. Otherwise I’m off!!! ---
**Author:** ![thebigone2087](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/t/d6d6ee/32.png) [@thebigone2087](https://forum.gbfans.com/u/thebigone2087)\ **Post date:** [April 25, 2014, 3:04am UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/11 "2014-04-25T03:04:33Z")
I love that idea for the [n-filter](https://www.gbfans.com/wiki/equipment/proton-pack/n-filter)!!! Are you then going to rivet it to the fiberglass ridge you made? ---
**Author:** ![drjameshouse](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/d/6a8cbe/32.png) [@drjameshouse](https://forum.gbfans.com/u/drjameshouse)\ **Post date:** [April 25, 2014, 3:25am UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/12 "2014-04-25T03:25:36Z")
> [@thebigone2087](#): > > I love that idea for the n-filter!!! Are you then going to rivet it to the fiberglass ridge you made? Yea, probably epoxy glue and rivet it. ---
**Author:** ![kurisu7885](https://forum.gbfans.com/user_avatar/forum.gbfans.com/kurisu7885/32/6555_2.png) [@kurisu7885](https://forum.gbfans.com/u/kurisu7885)\ **Post date:** [April 25, 2014, 5:56am UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/13 "2014-04-25T05:56:37Z")
I’m debating if I’ll swap out the N filter on my own build, and you guys make it look easy enough to make me want to make the attempt. ---
**Author:** ![kingpin](https://forum.gbfans.com/user_avatar/forum.gbfans.com/kingpin/32/187259_2.png) [@kingpin](https://forum.gbfans.com/u/kingpin)\ **Post date:** [April 25, 2014, 1:08pm UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/14 "2014-04-25T13:08:20Z")
> [@drjameshouse](#): > > I decided if I was going to do something, I might as well over do it. I am definitely a supporter of over-engineering. It didn’t hurt the Victorians, so it shouldn’t hurt us. 🙂 Nice work on the [N-Filter](https://www.gbfans.com/wiki/equipment/proton-pack/n-filter) replacement. ---
**Author:** ![kurisu7885](https://forum.gbfans.com/user_avatar/forum.gbfans.com/kurisu7885/32/6555_2.png) [@kurisu7885](https://forum.gbfans.com/u/kurisu7885)\ **Post date:** [April 25, 2014, 5:16pm UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/15 "2014-04-25T17:16:12Z")
Hey, some healthy over-engineering brought us the steampunk genre, which itself brought us some nice packs. ---
**Author:** ![drjameshouse](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/d/6a8cbe/32.png) [@drjameshouse](https://forum.gbfans.com/u/drjameshouse)\ **Post date:** [May 16, 2014, 4:34am UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/16 "2014-05-16T04:34:12Z")
Update Time!!! Well I have been working on it since the last update, but I really didn’t feel like much got done so I hadn’t updated the thread. Now that I look at all the pictures I guess I did get more done that I thought! So let’s just get started! First I continued on with the [N-Filter](https://www.gbfans.com/wiki/equipment/proton-pack/n-filter). I spent an entire day in Photoshop and Solidworks looking at reference pictures figuring out the uneven spacing of the holes. I started with the Murray Pack shoot photos and using weld patterns and weathering found the degrees between each hole if you were looking at the top of it. Think pie graph. Then I started over with the Sony Lobby Hero pack they both actually came out the same (or pretty damn close). Then using maths I found the distance between center holes and altered Namssorg’s evenly spaced template (with permission). I had a hell of a time since I had never used illustrator but I got it good enough for my purpose. By the way, I am working with Matt to update his template and we will be making it public, so if anyone wants to take advantage of my hours and hours of research for uneven hole placement they can. Anyways, I cut the template out and taped it on so the holes would be 1/2" below the weld line. Then I figured I needed a jig/holder for the N-Filter for when I drill the holes so using a hole saw and a 2x4 I came up with this I took it to the drill press, and using a step drill bit drilled out all the holes. Next, since I didn’t like the gaps between the N-Filter and shell I started building up the edges with epoxy putty and filler. I ended up doing this several times as I would end up sanding too much off in a particular area and wouldn’t bee happy with the fit. It would have been really easy just to do a fake weld, but it’s not accurate and I don’t really like that look. I also thought it would be easier to get as tight of fit with the N-Filter removable than to glue the sucker in place and then fill in since sanding in a corner is a nightmare. Anyways it ended up looking like this: I also filled in the bottom edge that hung over with epoxy putty: And sitting in the shell: Now I turned my attention to the [bumper](https://www.gbfans.com/wiki/equipment/proton-pack/bumper). I have both a Venky bumper and a Bigi bumper. After placing both on the shell I decided to use the Bigi as it just fits so nicely to it’s shell. The Venky is a little wider and even when pinched together just didn’t sit as nice on the shell. I also decided to take the seam off since most of the actual screen shots in GB1 I was looking at didn’t have the seam. I’m not sure if it just didn’t show up on screen or if the seam was more prominent on certain packs. I also filled in some of the air bubbles in with filler and just sanded it smooth. Next I hung it up for painting, and shot it with primer. And that’s all I’ll update with tonight since it’s getting late I have to work early tomorrow. Tomorrow I’ll update with the rest of the work I’ve done up to now! ---
**Author:** ![nick-a-tron](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/n/fbc32d/32.png) [@nick-a-tron](https://forum.gbfans.com/u/nick-a-tron)\ **Post date:** [May 16, 2014, 5:32pm UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/17 "2014-05-16T17:32:16Z")
Fantastic build so far!! You sir have talent! ---
**Author:** ![drjameshouse](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/d/6a8cbe/32.png) [@drjameshouse](https://forum.gbfans.com/u/drjameshouse)\ **Post date:** [May 16, 2014, 11:53pm UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/18 "2014-05-16T23:53:40Z")
> [@nick-a-tron](#): > > Fantastic build so far!! You sir have talent! Thanks Nick! That means a lot coming from someone as talented as you! And since Nick commented I’ll start off with the [Legris](https://www.gbfans.com/wiki/equipment/proton-pack/legris) Replica’s I bought from him. I have gen 2’s and I have a gen 1 1/8" legris elbows, but the threads on those are smaller than the pre-drilled holes on my HGA. So this is what I started with: I cut the excess off of them, and sanded down the casting line. Then using the dremel and a small engraving bit ground out holes for the inserts. Here is the bit I used: As a side note, if people have never seen or used the flexible attachment for a dremel I highly recommend it. It’s easier to handle and get into tight places: Here’s what the elbows looked like making the holes, sanding, and a little putty: I then painted them. For those who are not aware, Krylon Gray Primer is a really good match. The only kind I could find was flat gray, so I followed them up with a satin clear coat. Here they are all painted: After painting I was able to just press fit the insert where the hose pushes in, and I used some epoxy putty to put the insert with the hose barb and threads. Here’s a shot of one installed after drilling and tapping the shell: I then started mounting the beam, filler, and vacuum tubes, along with the HGA, [Injectors](https://www.gbfans.com/wiki/equipment/proton-pack/injectors), and Clippard. Pretty straight forward, just made a paper template of the base of each, marked where the mounting screw goes on the shell, drilled it out and mounted them using 1/4"-20 socket cap screws from inside the shell. Here’s a shot of them installed: I also drilled and tapped for the legris straights. You can see them installed in the above picture, but here’s a closeup: The PPD was just sitting there in that shot, so I decided to take care of that next. I looked at reference images to get the angle and height placement, and then taped the sucker down. Then I carefully drilled holes from the inside, and tapped them. The holes on the shell I drilled out bigger so that I had a little bit of adjustment. Next I decided I should take care of the [power cell](https://www.gbfans.com/wiki/equipment/proton-pack/power-cell) opening thickness. Just like the [cyclotron](https://www.gbfans.com/wiki/equipment/proton-pack/cyclotron) holes I wanted to make sure I got the opening thickness even all the way around. So I made yet another jig. Similar concept as the cyclotron: And finished: ---
**Author:** ![drjameshouse](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/d/6a8cbe/32.png) [@drjameshouse](https://forum.gbfans.com/u/drjameshouse)\ **Post date:** [May 17, 2014, 2:12am UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/19 "2014-05-17T02:12:33Z")
While all the above work was going on my assistant Bo was a little in the dumps since the last 2 weeks in Iowa have been near non-stop rain looking similar to this: (The fence is to keep him from going in the more muddier part of the yard where I am attempting to regrow grass) At this point I decided to tackle the [Booster Tube](https://www.gbfans.com/wiki/equipment/proton-pack/booster-tube) and [Ion Arm](https://www.gbfans.com/shop/aluminum-welded-ion-arm). I first set the Ion Arm on and right away noticed the dip in the shell: As you can see the bottom corner has quite a gap. I took out my straight edge to analyze how bad the dip was: So my first attempt to remedy it was to take a very strong blow dryer and heat the fiberglass up and attempt to push the dip back out. This helped a little but there was still more work to do. So I got out the body filler and coated the entire area: Then sanded, and coated some more: Then sanded again and got it pretty darn good. Then I marked where the holes in the shell for the booster should be and drilled the shell: I made those holes a little oversize as well just so I had some adjustment later. Then taped the ■■■■ out of the booster (like I did with the ppd) and drilled holes in the booster from inside the shell. Sorry I didn’t take any pictures of that, but it’s pretty straight forward. I then took the template for the Ion Arm Vince provided and drilled holes for the ion arm and mounted that as well. When I tightened the Booster tub down it had a tendency to want to pull ever so slightly away from the angled EDA. This didn’t make me very happy, and I wasn’t sure what I wanted to do. Some packs have a fake weld line there and others didn’t. I didn’t want one so I decided that I needed a plate at the end of the booster tube that I could drill and tap for a screw that would suck the tube into the EDA. Now I own a TIG welder, but I had never actually welded aluminum before. So I went down the a welding fabrication shop that also sells metal and rummaged through their aluminum scrap bin to find some 1/8" aluminum. I asked they guy how much and he laughed and told me bring whatever I didn’t mangle back to throw back in the pile. So I came back home, and last weekend I spent both Saturday and Sunday practicing laying beads down. Then welding ■■■■ pieces together. Most of it wasn’t real pretty at first, but with the aid of YouTube and persistence I started getting the hang of it. With some of the left over scrap I hadn’t used yet for practice I cut a piece that fit in the inside of the tube. Then I took the plunge and welded the sucker in. CAUTION: For those who don’t like ugly welds AVERT YOUR EYES NOW! It didn’t turn out very pretty as I hadn’t practiced welding recessed pieces inside tubes and it proved to be a little bit more challenging than lap and tee joints. Is it pretty? No. Did it do the job? Yes. I drilled and tapped it and mounted it back on the shell and now the Booster Tube is tight against the EDA. So after lots of practice welding, and one ugly welded piece down, I decided the next logical thing to do was join the Booster Tube to the Ion Arm. We all know there is a rod that is welded there, and it looked like 1/2" to me, so I went to the hardware store and paid WAY too much for it. I really didn’t feel like driving the 40 miles back to the fabrication shop, so I felt justified in paying a little more than I could have. Anyways I cut a piece off, laid it in between the Booster and Ion Arm and then tacked the rod to both the Booster and Ion Arm while mounted to the shell. I was really afraid that it might get too hot and cause damage to the shell, so I was extremely cautious and let the aluminum cool between each tack. After they were tacked and wouldn’t come apart, I unmounted the pieces from the shell and completed the welds on the rod. And the results… SUCCESS!!! Here’s a closer shot of the weld after I remounted the pieces to the shell: I thought I did a pretty good job for only welding aluminum for less than a week! After that I figured I should mount the [Booster Plug](https://www.gbfans.com/wiki/equipment/proton-pack/booster-plug). I made a mark on the plug of about where I wanted it to stick out…then removed the top Booster Tube mounting bolt, stuck the plug inside the Booster (after sanding the disk to fit inside the Booster Tube) and marked the bracket through the hole. Then I drilled and tapped the bracket of the plug and installed it on the shell: And for anyone interested, here is an inside shot of the shell showing the 3 bolts holding the Booster Tube (and plug) onto the shell, along with the 4 bolts mounting the Ion Arm. And now ladies and gentlemen you have been caught up with my progress so far. Tomorrow I plan on drilling the remaining holes for the [crank knob](https://www.gbfans.com/shop/crank-knob) and hoses, mounting the shell to the [motherboard](https://www.gbfans.com/wiki/equipment/proton-pack/motherboard) and then alice frame, and hopefully by the end of the day I will be spraying texture. So the big question of the night: What do you guys think? Anything I missed or should fix/do differently? I would love to hear everyone’s thoughts! Cory ---
**Author:** ![PssdffJay](https://forum.gbfans.com/user_avatar/forum.gbfans.com/pssdffjay/32/6529_2.png) [@PssdffJay](https://forum.gbfans.com/u/PssdffJay)\ **Post date:** [May 17, 2014, 2:23am UTC](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707/20 "2014-05-17T02:23:09Z")
I’m impressed! I’m writing down lots of notes for when my parts arrive! [Next page](https://forum.gbfans.com/t/drjameshouses-gb1-proton-back-build-now-textured/22707.md?page=2)