So I finally worked myself up to start on my pack today. I’ve been weighing the options of building materials for the past few weeks, thinking of using MDF, but since I had a bunch of 1" insulation foam board laying around, I figured I’d try that first. The stuff cuts like a dream on a bandsaw, and will be extremely light but also fairly stable.
Most of the pack will be made using this foam board, then I’ll use styrene sheets glued onto the foam to protect it a bit more from accidents and for a smooth surface to paint. My plan is to make the pack (and gun) look as good as possible but also spending as little as possible so I can afford to get a nice lighting kit for them both (I like lots of blinky lights :lol: ).
Haven’t decided on what to use for the motherboard, any suggestions?
Just a few pictures of the Ion Arm and booster/EDA box in foam, and a few other boxes for the gearbox and crank gen.
looking great! very neat.
looks good. I’m doing the same thing for weight purposes. I have one full foam and a hybrid foam/mdf in progress
Thanks guys! This project has actually evolved a bit since my initial post. Instead of a full insulation foam pack (which I have full faith that it can be done with spectacular results), I have decided rather than to make a one-off pack, I’d try my hand at making bucks for a vacuum-formed pack. I have a friend who built a custom vacuum table with a 2x2 forming surface, so hefty start-up costs won’t be a factor. Plus if I succeed at creating a good quality vacuum-formed pack, I’ll have the ability to quickly make more if friends ever wanted to embark on a Ghostbuster costume.
I know the disadvantages of a vacuum-formed pack, but I think this will work better for me. The plan will be making the forms from foam, then for the top layer I will use a sturdier material, most likely wood, to spread out the pressure of the vacuum so it won’t crush the foam. The sides will also be covered in putty to strengthen them as well.
Hopefully by the beginning of March I will have a finished vacuum-formed shell to start work on, assuming there are no kinks in my plan. :lol:
Got the cyclotron and the spacers/cosmetic plating done. I still have to add the rings to the cyclotron, and the plating and spacer. Need to find some good putty to use, something that dries pretty hard and stable, but still sandable. Any suggestions on what to use?
are you compensating for the thickness of the foam for your styrene skin?
Yep, I’m making areas slightly bigger or smaller depending on where it goes.
A few more shots, almost done with the main shapes of the pack, then I’ll move on to the ribs.
