Finished my first pack (see the last page of that thread here Paul's Proton Pack (COMPLETE!) - #61 by enchanted_unicorn - Proton Packs - GBFans.com and leave your thoughts/opinions) and thought I would attempt another. This is going to be a slowwww build I think due to lack of funds, getting married costs a penny or two. Thought I would start the thread now and see where it goes.
Alright, so a it of an update. I bought a 9" by 2" cake pan that I realized I could not place on top of a 1/2" spacer as it would be too high. Therefore I had to cut out the 1/2" spacer, cut a hole to allow room for the cake pan, and then channel out some foam for the lip of the cake pan. I also cut away the foam around the outer edge by 1/2" to fold it down to protect the foam. Tedious? Yes. Necessary? In my opinion, yes.
Once that was done, I got started on the gear box. Took me a while, and fortunately I noticed a few mistakes BEFORE I cut it out, but it turned out great. I didn’t cut the angled middle section yet as I want to get the PVC first to ensure a good fit.
Easiest method to make fins? Anyone?
And here’s where we stand at the moment:
Don’t forget to check out my original pack: GBFans.com
Hey guys, thanks for the kind words and advice. Will definitely have a lookout for some basswood. So, did some work today on the gun mount. No fins yet, but I like how it is shaping up. Also cut the cosmetic plating out of 1/2" foam board. as well as the corner plate. That’s all for now.
Mine is solid wood, and someone almost tore it off our first event night out 2 years ago. (Halloween) The bumper and the ion arm and gun take the most abuse.
Bit of an update. I put some quarter round in the corners of all of the parts I’ve built. I also began to bolt everything together. A bit tricky at times, but everything feels solid. Today, I also today caulked the seams of all the parts. Gotta wait for the caulking to dry and sand it smooth. Stay tuned!
If anyone is wondering, the caulking I used was specifically for foam board and yes, it’s like working with peanut butter.
Awesome. As for the Ion Arm, I filled mine with expanding foam, capped it with 1/4" balsa, then used dowels to anchor it. Super sturdy, considering it’s foamcore. Also, as I learned the hard way, expanding foam contracts a bit after expanding that will cave in the sides (resulting in me making a 3rd Crank Generator and 2nd Ion Arm… ) And for the spacer, brace the ever living hell out of it. I didn’t consider everything that was going to be mounted to it (Cyclotron, Bumper, and chunky Shockmount) and ended up making a 2nd one that I’m pretty sure I could beat someone to death with.
Yeah, I’ve been thinking about the spacer. I’ve got wooden pieces on every flap for support (pics to come). I figure I’ll put two larger wooden blocks inside the spacer, attach them to the motherboard and then attach the bumper to them, hopefully having them take the weight instead of the cyclotron. My cyclotron is just a cake pan so no real weight there, but I am a bit concerned about the collapsing expanded foam. If it’s going to collapse, is there any point in putting it in there to begin with?
I used foam to make it rigid and give it support. Like with an empty box, it’s easy to wiggle, get off square, and collapse if bumped or dropped. But if solid, it’s not going to go anywhere. It’s kindof like when people fiberglass the inside of vacuform shells.
edit:And the collapsing is only a problem if you fill the piece completely all at once. If you run the foam along the inside corners, allow to dry, then spread the walls leaving the center open. If the middle’s open it can’t draw the walls to the center. I guess it’s not really necessary, but I was just extremely paranoid that I’ll drop it or bump it and cave a piece in and have to rebuild a section…
Here’s a few pictures of the supports I have so far. I also put a block of wood in the gunmount. I’ll secure the block of wood to the motherboard directly so that the weight of the gun doesn’t damage the gunmount foamboard box.
Deekman and Gareee, that is all excellent advice. Thanks!
Since the gunmount block mounts directly to the motherboard, I’d just make it out of solid wood. You are going to have a layer of foamcore now between your gun and your gunmount.
One of the worse sounds you will ever hear: The sound of your gun shattering on the floor.
If I put screws through the dixie style v-hook and spacer, through the foam and into the wood, and the wood is attached to the motherboard, won’t that be enough? I figured the foam was just aesthetics for this particular part of the pack.
I don’t know if I’m explaining this enough, I’m tired.
) And for the spacer, brace the ever living hell out of it. I didn’t consider everything that was going to be mounted to it (