I’m starting off on construction of my second pack. The first was a quick halloween job thrown together in a few weeks, and made from tri-wall card and bits that looked about right. It was the right shape, the measurements were correct, and the detail was okay. As I made it, though, I promised myself I would make a proper go of a sturdy prop that would do justice to all the years I’ve loved the films.
So two years later I have an alice frame, a very battered cardboard reference, this forum, and a sense of happy determination.
I’m only at the planning stage at the moment, but I’d like to throw myself on the experienced mercy of the board to point out any potential mistakes or minefields. I’ve a fairly reasonable idea of where I’m going thanks to my last effort, but obviously the materials are very different. To make life trickier I’ve not got much in the way of facilities other than a semi-spare room and a yard. Still, I like to think I’m resourceful enough to overcome minor obsacles like that.
So, the plan:
Motherboard
I plan to mount the pack on a wooden motherboard, most probably ply. I can cut this myself and it should be relatively easy for me to work. The aluminium motherboards look great and are probably lighter, but I’d struggle doing anything other than drilling it, and I’d like to have the option of screwing the other components into it for sturdiness. I can also use U clips to attach it to the alice frame so I can remove it if need be for storage or transport, but that might not be necessary. My main concern here, aside from weight (which I don’t think is a major issue), is that the grain will show after it’s painted.
Spacer
I’m expecting this to be tricky due to the curves, but I’m hoping Norm’s embroidery ring suggestion will get me through most of the problems here. As with much of the pack I’m planning on using ABS plastic, mounted on a wooden frame. Hopefully this will be sturdy without being too heavy, and fairly easy for me to cut. For the thinner bases for the vacuum pump and modular valve I’m thinking of building up a few layers of ABS.
I’ve contacted JT94 with regards to buying one of his plastic Cyclotrons. Once I receive it I’ll consider what other work I need to do in this area, but I don’t imagine it being a lot. I’ve also ordered his filters for the red ports.
At the moment my easiest option seems to be a Pringles tube. I used one last time and it actually feels fairly solid once glued down. I might fill the top with a layer of ABS to get rid of the lip, and I have a strip of reflective red tape from my last project that’s used on aircraft and looks great for the red band. The little ports might be troublesome, so as it stands I’ll probably just paint them on. If I can find a better material I’ll reconsider them.
The bumper is one of my biggest concerns. Last time I made the sides then crossed between them with flat pieces. Card last time, ABS this time. I’m not entirely happy with that though, as the real deal looks more like one pressed piece of metal. Still, if need be I’ll build it like that then replace it later when I find a better solution. The resin bumpers look great but as far as I can tell they’re not made any more.
The Ion knob I’m hoping to make using the ‘flymo cord round a tube’ method. I like the thin thread look and it should weigh a lot less (and therefore put less pressure on the bumper) than washers. I’ll see what I can pick up easiest in the hardware store though in reality.
Powercell & Injectors
I’m expecting this to be a straightforward construction of wooden frame with ABS sides and detail. The injectors seem to lend themselves well to PVC pipes, which I’ll be trying to screw onto something as securely as possible because I found them to be easily damaged in my last project.
EDA Box & Booster
Again, the EDA box I plan on making from a wooden frame and ABS. Rather than try to make a cut out for the tube that will make the PPD I’ll just cut the PPD instead and secure it with lots of glue. The Booster I can hopefully make from PVC tube, although I’ve not tried to source tubing that big yet. A plastic bottle cap worked nicely for the bit at the top of the booster last time, but I’ll research that in more detail once I’ve got the big shapes made. The booster frame will be bought if at all possible, I doubt I can make anything nearly as good myself.
Ion Arm Assembly
Again, wood and ABS if possible. The angle might be tricky, but I think I should be okay. I’ve bought the aluminium tip with brass rod from JT94. Not absolutely neccessary, but I really think a metal part here makes a world of difference visually. The resistors I plan on buying from MMM.
Tubes, hoses, elbows and barbs
This is as good a time as any to mention them. I’m planning on buying the elbows and barbs, but the tubes are a dilemma as they’re not all in stock at MMM. I could probably get some CAT5 and paint it, or wait to see if any more comes in. The hoses I’m again buying from JT94. I expect they’re not too difficult to find myself, but since I’m buying other things and they’re not expensive I might as well get something I know will do the job. Last time I could only find grey hose and the black paint rubbed off very quickly as the hose moves a lot.
Gearbox & HGA
Again, the wooden frame and ABS construction. I’m hoping the vanes on the gearbox and powercell will be pretty easy with ABS, so that’s a nice bonus. The vacuum pump seems to be a fairly standard PVC tube, looking at Norm’s plans, so I’m not anticipating too many problems here. The crank knob I’ll try and get in resin from MMM again.
I’d like to make the HGA myself with some pipe, as suggested in Norm’s plans. The weld lines around the end make me think that glueing an ABS cap on there would look quite good. If not, I can always buy one.
Gun Mount
This I plan on making from ply, as I’d like it to be tough enough to withstand me drunkenly tugging the gun from it. Again there’s the problem of the grain, but I’m wondering if a thick coat of paint cover that as well as making the whole structure look a little more rounded. The vanes can be made from ABS again though, and I’ll certainly be buying the mounting plates because there’s no way I could make anything I’d be happy with myself. The spacer between the mount and the gearbox will probably be ABS again unless it proves easier to build it as part of the gun mount.
Cosmetic Plating
I’m going to attempt to shape a piece af ABS for the left had piece where the ribbon cable (which I’ll be buying along with its various retainers) goes, but if need be I can build up a few hollow layers then cap it with an ABS plate. The other pieces I’ll layer from ABS and file any details so it fits, as well as the bevel on the corner piece. The pieces round the bottom of the spacer should suit little ABS plates perfectly.
Proton Gun
The whole gun I’m concerned about, as I didn’t make such a good job last time. I’d like to build the block myself, but I’m thinking that buying a resin one might yield better (and more solid) results. I’m concerned about drilling it though as resin is apparently prone to shattering. The details I’ll be buying from MMM hopefully, which reminds me that I’d like to have real Clippard valves if I can find them. I’ll have to research that further, but even though I’m not bad at detailed painting I don’t think I could make a resin valve look as good as a metal one.
Come to think of it, I suspect I’ll be buying most of the gun. The last attempt was less than satisfactory, so I’m kind of treading new ground with it as I didn’t learn a lot last time. I’m sure the forums here will come in handy though.
Electronics
I’ve made moves to procure one of JT94’s sets for the lights. This is the one area where I could go it alone as an electronics engineer, but I haven’t the facilities or, to be honest, the inclination to scratch build a circuit when there’s a great one out there for less than the cost of equipment and prototypes had I done it myself. Audio is a different matter entirely. I hadn’t even considered it until I reminded myself just how fantastic a proton pack sounds when it powers up. It’s one of those sounds that sticks in the memory, like a TIE fighter or the pulse rifle from Aliens. I’ll be looking onto it further, but for now I’ve got plenty to chew on.
So that’s the wall of text that constitutes my initial plan. It seems reasonable to me, but you guys are the veterans. Maybe nobody will read it, but hopefully at the very least people can look at pictures of the finished pack sometime before halloween 2009 and look back at how it started. I’ll be updating as I go. Wish me luck.