Foam Pack Build

Equipment Proton Packs
1

Okay so as a few of you know, every pack I’ve attempted to build… ever, went bust, and this includes the one I started last year. I’ve decided to actually fall back on my fallback plans of building a foam one out of construction foam from home depot. Assuming all I’ll need is one of those like… 3’x7’ sheets of pink foam and a hot knife, what would be the best medium of dimensions for this, since I won’t have to build it the same way as the others. Has anyone else tackled this? Any tips, etc?

2

no one has done a foam pack yet?

3

I’ve built one pack from that foam,sorry no pics,and it’s easy to work with but it takes so much more time and effort to coat the entire thing with bondo and sand it smooth,but it makes for a light pack.

Also,do not use a hot knife,it can cause the foam to catch fire.Just use a simple hacksaw blade to do all your cuts and then a fine grit sandpaper to even any edges out.

4

My pack is built out of foamcore/foamboard.

All my pics, including build pics, are in my profile

5

see i was afraid to use a hacksaw, but if you think the sandpaper can handle it smoothly (pun) then I’ll take your word.

6

Check my wip thread.. many if it’s parts are made from insulation foam.

7

Most of my pack is all foam board. The whole pack is very light weight, but on the down side if it was damaged at all the whole thing would prob colapse on itself.

8

Mine is pretty sturdy.. it took hellish abuse at halloween in a very crowded party, but held up fine.

Mines about 50% foam, 50% other materials for strength. Our packs and guns with the alice frames weigh in less thebn 12 pounds total! We were actually dancing in them at halloween!

9

Hi there,

I too am making a pack out of foam. I recommend getting 1 sheet of 3/4" and 1 sheet of 1/2". I was able to make all the major components by gluing different combinations of thickness together. I was able to lay out all the pieces in the time it took to watch the matrix ( haha it was on TNT) that includes gluing them up and the drawing the cut lines on the top piece of foam. Tomorrow, I’m going to take the pieces into work and cut them on the bandsaw. I was going to try the hack saw but when I made my first cut and saw how choppy it was, I decided to not rush and just do it right. I’ve cut foam rough before with hand saws ( yay all nighters in college)!and used a sanding block to get a clean side but with access to the bandsaw it will make the whole process shorter and cleaner ( no foam dust in the apartment :slight_smile: )