I am trying to see if there is a way to get the best of both worlds. I like the HasLab proton pack because of the viewable cyclotron and removable cover but I love the Hero pack. Why can’t I have both? Is there a way for me to have my Twinkie and eat it too?
What’s holding you back? The cyclotron cover is held on in universe by the bumper and bellows/bolt. Just because we never see them remove the cover in the first film doesn’t mean it’s not to spec with a hero pack if everything else is the correct size and part.
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In Adam Savage’s one day proton pack build video, it looks like he has a normal shell, i.e., non-Hasbro/Haslab, with the cyclotron lid removed so he can build his own inner cyclotron:
I don’t think I’ve seen a traditional body shell for sale like this with the lid removed, most of the ones you can buy are fibreglass and all in one, but I’m sure it wouldn’t be too hard to separate them using something like a Dremel, and that’s probably what Adam did here.
I think if I was doing this (and I’ve thought about it too), I think it would be hard to get a perfectly clean cut with one body shell. Probably not impossible, but it might be cleaner to buy two body shells, one for the body with the lid sacrificed, and the other vice versa. Or perhaps sacrifice the original lid and replace with a 3D printed version?
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As others have said, there’s no reason why you can’t have a functional Cyclotron cover… Much like the power switch on the underside of the Ion Arm, these elements can be retroactively made canon with the 1984 and 1989 Proton Packs. 
(As a minor bit of Mod business, I edited the title to make it a little clearer what it was referring to )
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I’ve thought about the process to make this work and I agree, however I had the thought that I could vacuum form the shell to cut the cover off of it instead of sacrificing the hero pack. From there I could create molds and fiberglass castings. Could create a few new mods.
If you have the ability, it would be nice to have backups while experimenting if it is a really nice shell.
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Much appreciated