# My Aluminium Scratch build pack adventure (Pic Heavy) **URL:** \ **Category:** Proton Packs\ **Created:** [December 5, 2014, 1:33pm UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701 "2014-12-05T13:33:55Z")\ **Posts on this page:** 20\ **Page:** 5
**Author:** ![galeap](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/g/dbc845/32.png) [@galeap](https://forum.gbfans.com/u/galeap)\ **Post date:** [September 7, 2015, 12:52pm UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/81 "2015-09-07T12:52:34Z")
Hi guys Its been a couple of weeks so I thought that I would report in with a build update. Not a huge amount of progress unfortunately. I’ve made the [injector tubes](https://www.gbfans.com/shop/aluminum-welded-injectors) up, and cut out the parts for the [beam line](https://www.gbfans.com/shop/aluminum-welded-beam-line) and [filler tubes](https://www.gbfans.com/wiki/equipment/proton-pack/filler-tubes), ppd and [booster tube](https://www.gbfans.com/wiki/equipment/proton-pack/booster-tube). Here is a couple of photos of a quick test layout tonight on my MDF [motherboard](https://www.gbfans.com/wiki/equipment/proton-pack/motherboard) template. All tubes, [cyclotron](https://www.gbfans.com/wiki/equipment/proton-pack/cyclotron) rings and the HGA are sitting loose roughly in place. Hopefully I’ll get a run at the build this weekend and I can finish the tube builds. [![image](https://discdn.gbfans.com/original/3X/b/c/bc34534628d51063b0ddebf708145f0962447614.jpeg)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/2015-09-07%2022.32.04_zpsdkxg5udb.jpg.html) [![image](https://discdn.gbfans.com/original/3X/3/4/341add4373b4fb65ba829c611be66276066d8414.jpeg)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/2015-09-07%2022.31.15_zpsnestothz.jpg.html) Cheers Pete ---
**Author:** ![csullivan1980](https://forum.gbfans.com/user_avatar/forum.gbfans.com/csullivan1980/32/19486_2.png) [@csullivan1980](https://forum.gbfans.com/u/csullivan1980)\ **Post date:** [September 7, 2015, 2:29pm UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/82 "2015-09-07T14:29:56Z")
This is the most amazing thing I’ve ever seen! ---
**Author:** ![cpu64](https://forum.gbfans.com/user_avatar/forum.gbfans.com/cpu64/32/104792_2.png) [@cpu64](https://forum.gbfans.com/u/cpu64)\ **Post date:** [September 14, 2015, 7:15pm UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/83 "2015-09-14T19:15:16Z")
Soon we’ll be able to start a metal pack club 😃 Looks great! ---
**Author:** ![barison82](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/b/ecccb3/32.png) [@barison82](https://forum.gbfans.com/u/barison82)\ **Post date:** [October 9, 2015, 6:44pm UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/84 "2015-10-09T18:44:14Z")
Absolutely awesome! This is one hell of a build…it will be something very special when it’s finished. Just noticed your location - my other half is an Aussie and her family are also in Brisbane, we go out there every year to visit, they live in Samford. I will follow this epic build with great interest, thanks for sharing it! Alex ---
**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:** [October 16, 2015, 10:05am UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/85 "2015-10-16T10:05:55Z")
My dreams are now filled with amazing metal pack builds. ---
**Author:** ![galeap](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/g/dbc845/32.png) [@galeap](https://forum.gbfans.com/u/galeap)\ **Post date:** [November 16, 2015, 10:59am UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/86 "2015-11-16T10:59:38Z")
Hi everyone, It’s been a while since my last post so thought it was about time for an update. I have competed the centre section of the pack and connected the three sections into one to form the shell. In the end I bolted the sections together. There is a few minor gaps around the pieces that I will fill with epoxy and create a small fillet at the same time. This will be next weekend’s task. Couple of photos showing the centre section coming together. [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20151024\_183325\_zpstihsw9gz.jpg)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151024_183325_zpstihsw9gz.jpg.html) [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20151025\_165524\_zpso9dvohwb.jpg)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151025_165524_zpso9dvohwb.jpg.html) [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20151108\_162400\_zpsnyieqrt0.jpg)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151108_162400_zpsnyieqrt0.jpg.html) The photos below is with the shell complete, but all the tubes just loosely placed to see how it looks all together so far. Also the [cyclotron](https://www.gbfans.com/wiki/equipment/proton-pack/cyclotron) washers need to be glued down into their final spots. [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20151115\_222901\_zpsqwfomhqg.jpg)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151115_222901_zpsqwfomhqg.jpg.html) [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20151115\_222922\_zpsfgah4nkh.jpg)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151115_222922_zpsfgah4nkh.jpg.html) [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20151115\_222932\_zpsbr8ng53a.jpg)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151115_222932_zpsbr8ng53a.jpg.html) [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20151115\_222950\_zpsbaphcyw9.jpg)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151115_222950_zpsbaphcyw9.jpg.html) [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20151115\_223024\_zpstjnhgdtr.jpg)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151115_223024_zpstjnhgdtr.jpg.html) So next will be to finish up the ppd tube and make up the [motherboard](https://www.gbfans.com/wiki/equipment/proton-pack/motherboard). Then it’s on to the all aluminium [bumper](https://www.gbfans.com/wiki/equipment/proton-pack/bumper). Pete. ---
**Author:** ![csullivan1980](https://forum.gbfans.com/user_avatar/forum.gbfans.com/csullivan1980/32/19486_2.png) [@csullivan1980](https://forum.gbfans.com/u/csullivan1980)\ **Post date:** [November 16, 2015, 11:11am UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/87 "2015-11-16T11:11:38Z")
I’m jealous! Awesome work. One of a kind!!! ---
**Author:** ![ocp\_model-001](https://forum.gbfans.com/user_avatar/forum.gbfans.com/ocp_model-001/32/187055_2.png) [@ocp\_model-001](https://forum.gbfans.com/u/ocp_model-001)\ **Post date:** [November 16, 2015, 10:09pm UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/88 "2015-11-16T22:09:32Z")
Lovely work Pete! She’s looking well. Keep it going lad 😉 ---
**Author:** ![twmedford23](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/t/48db29/32.png) [@twmedford23](https://forum.gbfans.com/u/twmedford23)\ **Post date:** [November 17, 2015, 6:05am UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/89 "2015-11-17T06:05:19Z")
Do you HAVE to paint it? ---
**Author:** ![galeap](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/g/dbc845/32.png) [@galeap](https://forum.gbfans.com/u/galeap)\ **Post date:** [November 17, 2015, 12:02pm UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/90 "2015-11-17T12:02:41Z")
Hi guys. Thanks for the kind words. While not perfect by any measure I’m happy enough with how it is coming together so far, especially since I’m teaching myself to tig weĺd on the fly. twmedford23, a few people have suggested not painting it, but I’m keen on making it look like a movie hero pack. Once I have it all done I’ll do a few photos prior to painting (maybe without the thrower though). Pete. ---
**Author:** ![twmedford23](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/t/48db29/32.png) [@twmedford23](https://forum.gbfans.com/u/twmedford23)\ **Post date:** [November 18, 2015, 7:31am UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/91 "2015-11-18T07:31:12Z")
It really is an insane build. Are you going to full GB1 hero or will you possibly do a GB2 style hero? I’m hoping GB2… > [@galeap](#): > > Hi guys. > > Thanks for the kind words. While not perfect by any measure I’m happy enough with how it is coming together so far, especially since I’m teaching myself to tig weĺd on the fly. > > twmedford23, a few people have suggested not painting it, but I’m keen on making it look like a movie hero pack. Once I have it all done I’ll do a few photos prior to painting (maybe without the thrower though). > > Pete. ---
**Author:** ![galeap](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/g/dbc845/32.png) [@galeap](https://forum.gbfans.com/u/galeap)\ **Post date:** [November 18, 2015, 8:58am UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/92 "2015-11-18T08:58:19Z")
> [@twmedford23](#): > > It really is an insane build. Are you going to full GB1 hero or will you possibly do a GB2 style hero? I’m hoping GB2… > > > [@galeap](#): > > > > Hi guys. > > > > Thanks for the kind words. While not perfect by any measure I’m happy enough with how it is coming together so far, especially since I’m teaching myself to tig weĺd on the fly. > > > > twmedford23, a few people have suggested not painting it, but I’m keen on making it look like a movie hero pack. Once I have it all done I’ll do a few photos prior to painting (maybe without the thrower though). > > > > Pete. Sorry I’m going for a GB1 hero build. I’m going to have to paint my [crank knob](https://www.gbfans.com/shop/crank-knob) grey if I can’t find a genuine one. Also I’m trying to chase down a GB1 [ribbon cable](https://www.gbfans.com/wiki/equipment/proton-pack/ribbon-cable) at the moment. P. ---
**Author:** ![galeap](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/g/dbc845/32.png) [@galeap](https://forum.gbfans.com/u/galeap)\ **Post date:** [January 1, 2016, 12:52pm UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/93 "2016-01-01T12:52:02Z")
Hi everyone, Firstly, Happy New Year everyone, I hope you all had a great Christmas. I’m long overdue on a build update, so this one will have a few photos of my efforts over the past few weeks. As previously mentioned I decided to have a go at making an aluminium [bumper](https://www.gbfans.com/wiki/equipment/proton-pack/bumper). I wanted it to be light so I decided to make a hollow bumper based off Steffan’s plans. Using Visio I made up a template and started work. Here are the side wallls based directly off the plans. [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20151213\_150935\_zpswmiwnv5r.jpg~original)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151213_150935_zpswmiwnv5r.jpg.html) However, as I started working out the top plate I noted that the side wall plans don’t line up correctly with the reference bumper photos on this site. Specifically, around the underside of the centre where the section tapers down. I ended up building the missing part back up with weld and progressed to make the top plate and centre wing walls. [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_2016-01-01 21.43.46\_zpsgvn1gkre.jpg~original)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/2016-01-01%2021.43.46_zpsgvn1gkre.jpg.html) [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_2016-01-01 21.46.25\_zpsoyqsjyvb.jpg~original)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/2016-01-01%2021.46.25_zpsoyqsjyvb.jpg.html) I welded these parts up and filed/sanded the edges out. [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_2016-01-01 21.49.32\_zpsi9vmhy0d.jpg~original)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/2016-01-01%2021.49.32_zpsi9vmhy0d.jpg.html) I made up the back plate in similar fashion to the top plate. [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_2016-01-01 21.51.02\_zpsqqpavynq.jpg~original)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/2016-01-01%2021.51.02_zpsqqpavynq.jpg.html) Did a test fit of the back plate. [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20151230\_155205\_zpsz0wwle70.jpg~original)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20151230_155205_zpsz0wwle70.jpg.html) Then weld on the back plate, welded up the ends and filed/sanded (and sanded some more) the edges back to finished the metal work. [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20160101\_183200\_zpsnrjimnvg.jpg~original)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20160101_183200_zpsnrjimnvg.jpg.html) [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20160101\_183046\_zpsl56hwfuv.jpg~original)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20160101_183046_zpsl56hwfuv.jpg.html) [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20160101\_182649\_zpsz3yblsag.jpg~original)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20160101_182649_zpsz3yblsag.jpg.html) [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20160101\_182701\_zpszeatnqcv.jpg~original)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20160101_182701_zpszeatnqcv.jpg.html) Test fist against the pack shell. [![image](http://www.gbfans.com/images/pb/galeaorama/Proton Pack Build\_20160101\_183432\_zpsvl2zoire.jpg~original)](http://s1369.photobucket.com/user/galeaorama/media/Proton%20Pack%20Build/20160101_183432_zpsvl2zoire.jpg.html) While not perfect, I’m quite happy with how it turned out given my developing welding skills. The next step with it will be to use some epoxy filler on the inside edges to create the taper along the fins. This will be tomorrow’s task. As a side note I found this to be the most difficult part to weld to date, but then again I think that I think that about each part somewhere along the line. Oh, and I’m still trying to find a good way to unclog aluminium from my files. Anyway, I hope that you guys/gals found this update interesting. Until next time, bye. Pete 🆒 ---
**Author:** ![Venkmans\_Swagger](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/v/6bbea6/32.png) [@Venkmans\_Swagger](https://forum.gbfans.com/u/Venkmans_Swagger)\ **Post date:** [January 1, 2016, 3:49pm UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/94 "2016-01-01T15:49:15Z")
Amazing!! This is 1 sick build. You can pick up a GB1 cable from EJ Gunth in the for sale section. I have 1 and its a thing of beauty ---
**Author:** ![EctoPrimer](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/e/a87d85/32.png) [@EctoPrimer](https://forum.gbfans.com/u/EctoPrimer)\ **Post date:** [January 2, 2016, 12:26pm UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/95 "2016-01-02T12:26:53Z")
Wow. Just wow. We need to build a plinth. This belongs in a museum ---
**Author:** ![csullivan1980](https://forum.gbfans.com/user_avatar/forum.gbfans.com/csullivan1980/32/19486_2.png) [@csullivan1980](https://forum.gbfans.com/u/csullivan1980)\ **Post date:** [January 2, 2016, 1:38pm UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/96 "2016-01-02T13:38:45Z")
Stunning! Absolutely stunning! ---
**Author:** ![Ejgunth87](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/e/c77e96/32.png) [@Ejgunth87](https://forum.gbfans.com/u/Ejgunth87)\ **Post date:** [January 2, 2016, 2:00pm UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/97 "2016-01-02T14:00:25Z")
I’m not sure of the exact name of it, but I use a wire brush to clean out debris from my files. It looks like a coarse hairbrush almost. I got mine at Lowe’s, I’m sure Home Depot would have it too. ---
**Author:** ![galeap](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/g/dbc845/32.png) [@galeap](https://forum.gbfans.com/u/galeap)\ **Post date:** [January 2, 2016, 11:25pm UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/98 "2016-01-02T23:25:01Z")
Hi guys. Thanks for the supporting words, it helps me stay motivated to see this project through. Ejgunth87, I have a file wire brush (the type with short bristtles) but it doesn’t seem to be able to get the larger burs of aluminum out of the file. In fact, I broke the plastic handle off it yesterday by pushing down to hard trying to clean one of my more clogged files. I have even tried running a piece of brass plate along the file (in the direction of the teeth), and this works well on removing the burs for the flat files but not on the half round one. So the search is still on for another technique. Pete 🆒 ---
**Author:** ![twmedford23](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/t/48db29/32.png) [@twmedford23](https://forum.gbfans.com/u/twmedford23)\ **Post date:** [January 3, 2016, 1:11am UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/99 "2016-01-03T01:11:41Z")
I’m having trouble reattaching my jaw after it fell to the floor. Just amazing! ---
**Author:** ![Alan\_Hawkins](https://forum.gbfans.com/user_avatar/forum.gbfans.com/alan_hawkins/32/4015_2.png) [@Alan\_Hawkins](https://forum.gbfans.com/u/Alan_Hawkins)\ **Post date:** [January 3, 2016, 6:53am UTC](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701/100 "2016-01-03T06:53:43Z")
Stunning! [Previous page](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701.md?page=4) [Next page](https://forum.gbfans.com/t/my-aluminium-scratch-build-pack-adventure-pic-heavy/20701.md?page=6)