# You can't polish a turd, but I'm gonna try! Vacuform Refurb **URL:** \ **Category:** Proton Packs\ **Created:** [September 30, 2014, 8:02pm UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025 "2014-09-30T20:02:23Z")\ **Posts on this page:** 20\ **Page:** 1
**Author:** ![Lowberg](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/l/46a35a/32.png) [@Lowberg](https://forum.gbfans.com/u/Lowberg)\ **Post date:** [September 30, 2014, 8:02pm UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/1 "2014-09-30T20:02:23Z")
Okay so my good buddy wants me to refurb this pack shell. It’s a very old vacuform shell and is in **horrendous** condition. No idea how it got this way… I really don’t WANT to know how it got this way, It’s been through several owners. Honestly I think it’s totaled but he doesn’t want to waste it. I’m looking at this as a challenge to see if I can pull this off and make it look decent. So here are the before pics… **I’m warning you, you might want to cover your eyes**. ![image](https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t34.0-12/10681757_846988735320972_610962102_n.jpg?oh=df108a533247b73930088b8fdf7d1abe&oe=542D81F9& __gda__ =1412208484_4ec0c551348796d4c3c47acce839c6f9) ![image](https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpa1/v/t34.0-12/10668460_846988768654302_1872497366_n.jpg?oh=697514542e7093fa095eff75345f8fe5&oe=542DCC55& __gda__ =1412214325_095af7f7333e8584838d18fcd5b4f55b) ![image](https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t34.0-12/10708101_846988825320963_309901534_n.jpg?oh=8f01e7376d8a0753ccd753b614f5a2b7&oe=542DB8F3& __gda__ =1412266862_2950ef9df5ecd55cc61b628d7de5a482) ![image](https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t34.0-12/10706474_846988875320958_458240474_n.jpg?oh=8a315bab5149d28508ee611d095a9050&oe=542CC60F& __gda__ =1412275026_373fec56d6ef22f883de6bb1f286a071) ![image](https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t34.0-12/10707906_846988938654285_1103544639_n.jpg?oh=865f102ea65867065fd1f0f5b9e3f3f3&oe=542D9124& __gda__ =1412287092_28b33c070f797d79bb4845a96208683a) and the worst of all…_shudders_ ![image](https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t34.0-12/10711409_846989055320940_1589284076_n.jpg?oh=d589737c1667976cf7eff2520d726d14&oe=542D8E35& __gda__ =1412293605_3943df15923ef812ef723b85c901e51d) This thing is beat up, all jagged, webbing everywhere, GIANT sections removed, doesn’t fit together, cracked and god knows what else ---
**Author:** ![Lowberg](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/l/46a35a/32.png) [@Lowberg](https://forum.gbfans.com/u/Lowberg)\ **Post date:** [September 30, 2014, 8:10pm UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/2 "2014-09-30T20:10:32Z")
First thing I did was strip all garbage parts down. My buddy Nick is providing me with all quality parts so the first plan is to get the shell in a workable condition. The first owner made the [Ion arm](https://www.gbfans.com/shop/aluminum-welded-ion-arm) riser tower, the [booster tube](https://www.gbfans.com/wiki/equipment/proton-pack/booster-tube), and the [injector tubes](https://www.gbfans.com/shop/aluminum-welded-injectors) go THROUGH the shell so there’s giant holes cut out ugh I epoxied 1/8" styrene plates from the inside to all the areas that were cut out and in areas that needed support. After a few coats of bondo body filler, it’s starting to take shape. Final filling and smoothing will be done at a later state Next that N filter HAD TO GO Sent this picture to our GB Group chat on facebook 🙂 SO MUCH BETTER. We are using a Nickatron [N-filter](https://www.gbfans.com/wiki/equipment/proton-pack/n-filter). This will be attached later on but we started to cut space for it ---
**Author:** ![KCGhostbuster](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/k/a9a28c/32.png) [@KCGhostbuster](https://forum.gbfans.com/u/KCGhostbuster)\ **Post date:** [September 30, 2014, 8:26pm UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/3 "2014-09-30T20:26:12Z")
Can’t wait to see where this ends up -good start. ---
**Author:** ![Gloomdrifter](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/g/58f4c7/32.png) [@Gloomdrifter](https://forum.gbfans.com/u/Gloomdrifter)\ **Post date:** [September 30, 2014, 8:39pm UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/4 "2014-09-30T20:39:22Z")
We can rebuild him. We have the technology. We can make him better than he was. Anyways, good looking work. Cleaning up that horrid [n-filter](https://www.gbfans.com/wiki/equipment/proton-pack/n-filter) made a big difference. ---
**Author:** ![Lowberg](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/l/46a35a/32.png) [@Lowberg](https://forum.gbfans.com/u/Lowberg)\ **Post date:** [September 30, 2014, 11:24pm UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/5 "2014-09-30T23:24:37Z")
I’ll probably need suggestions on certain parts! Everyone’s input is welcome. I’m considering sanding off the the EDA discs and filling that area flat. I’ just don’t want to compromise the structural integrity by removing more of the shell Hose hole/mousehole is going to get cut to the correct shape Considering cutting off the right side of the bottom half of the shell, it overlaps where you should just have the [motherboard](https://www.gbfans.com/wiki/equipment/proton-pack/motherboard) showing. All the other main parts are going to be PVC ([injector tubes](https://www.gbfans.com/shop/aluminum-welded-injectors), filler/line tubes/ riser tower, hga) to keep the cost and weight down ---
**Author:** ![syckotheklown](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/s/d6d6ee/32.png) [@syckotheklown](https://forum.gbfans.com/u/syckotheklown)\ **Post date:** [October 1, 2014, 12:24am UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/6 "2014-10-01T00:24:13Z")
The state of that pack has me terrified beyond the capacity for rational thought. BUT I agree with gloom, the n filter alone makes a big difference. It’s coming along though. I can’t imagine what the original builder was thinking with some of those braces though. A lot of unnecessary cutting into the shell. Must have severely weakened it all together. Definitely cut off that right side where the mobo shows though. And correct me if I’m wrong, it looks like it needs trimming on the left and around the entire edge where the ribs are. ---
**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:** [October 1, 2014, 12:45am UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/7 "2014-10-01T00:45:40Z")
Is this a 2nd generation SC shell? ---
**Author:** ![Lowberg](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/l/46a35a/32.png) [@Lowberg](https://forum.gbfans.com/u/Lowberg)\ **Post date:** [October 1, 2014, 1:29am UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/8 "2014-10-01T01:29:30Z")
Not too sure, it’s had a couple previous owners so I don’t know. Here’s it next to a 2014 SC shell I bought for my own build, to be finished after this one Don’t let this thread discourage anyone from buying a vac shell. The new studio creations one (Left) is WAY nicer and is a great value. ![image](https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t34.0-12/10612589_10100360184115383_9041264689340115980_n.jpg?oh=5ef995e92dda441ee9083737f69332ef&oe=542DB52C& __gda__ =1412275331_c403863d2c8bfbc92d34729b7fb1ba44) The shell had really weird multiple wacky mounting holes that were all off center and bent the shell out. I filled those tonight and flattened it all out ![image](https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t34.0-12/1932292_10100360184120373_3424880635760007926_n.jpg?oh=196f8174740696845f97d1e261809142&oe=542D8E32& __gda__ =1412283833_c68b4de3e6254e08bd4f14d5f043391f) ---
**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:** [October 1, 2014, 7:32am UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/9 "2014-10-01T07:32:36Z")
Those initial pics were horrendous. You’ve got it looking 100 times better already. You may well succeed in polishing said turd ---
**Author:** ![Lowberg](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/l/46a35a/32.png) [@Lowberg](https://forum.gbfans.com/u/Lowberg)\ **Post date:** [October 3, 2014, 1:22am UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/10 "2014-10-03T01:22:45Z")
Got rid of the brutal mounting holes, drilled them out and re enforced all corners with styrene from the inside. Then bondo’d over them to get the shell flat in those areas ![image](https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t34.0-12/10414519_10100361293272623_6875872456998359524_n.jpg?oh=4c21731270a498ea9ae98a811a42b7e0&oe=54301FFE& __gda__ =1412446609_4b3be565c3f36bcd8932f35f41f29d27) Started to clean up some of the webbing that the previous owner just cut right out. ![image](https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t34.0-12/10665675_10100361289764653_8577585322721836153_n.jpg?oh=fe8397f0c05e1fad1b4a269b1d8f61f5&oe=5430457C& __gda__ =1412433043_69c5601ddc56da7f12f885dc5b7ebe10) Filled all the poorly placed holes for mounting hardware ![image](https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t34.0-12/10703622_10100361281745723_2406461212371865538_n.jpg?oh=810e1a97ce844bb3b6a99a2d7747e2a5&oe=542FE4F2& __gda__ =1412507869_afbbc79096c40048f1ae969f03f53d0a) Lots of work to do before painting but I did some paint tests on scrap styrene.. Hammered Black, Satin Black, Flat Black. I’m thinking the satin black would look the best, but the hammered finish might hide some of the imperfections. Opinions? ![image](https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-xpf1/v/t34.0-12/10478442_10100361215298883_2210414363909757351_n.jpg?oh=0d9cd98faa7aec1b06494733abe98c72&oe=54300273& __gda__ =1412507932_1d11daaf97a5e04852ec1c837725e322) looks like some of my facebook image links are broken… sorry. I’ll start using imgur ---
**Author:** ![syckotheklown](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/s/d6d6ee/32.png) [@syckotheklown](https://forum.gbfans.com/u/syckotheklown)\ **Post date:** [October 3, 2014, 1:34am UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/11 "2014-10-03T01:34:12Z")
Looking great. I do agree with ya, the satin does look the best. But as you said the hammered will hide a lot. And with all the work youve got ahead on it, its gonna need all the help it can get. ---
**Author:** ![GreenSlimer\_2285-11](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/g/46a35a/32.png) [@GreenSlimer\_2285-11](https://forum.gbfans.com/u/GreenSlimer_2285-11)\ **Post date:** [October 3, 2014, 2:30am UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/12 "2014-10-03T02:30:07Z")
Alex it’s coming along amazingly well. Can’t wait to see how this one’s together in the end. I’m debating between the hammered black and the satin black. Satin black is more of the standard classic pack look, however you do have a point about the hammered aiding in the concealment of additional imperfections. I just want this to look the best that it possibly can for what it is. From Diarrhea to a solid floater, this will be a great light weight stunt pack coupled with a matty thrower. I’ll swing by tomorrow, bring some more parts and bounce some additional ideas. ---
**Author:** ![GreenSlimer\_2285-11](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/g/46a35a/32.png) [@GreenSlimer\_2285-11](https://forum.gbfans.com/u/GreenSlimer_2285-11)\ **Post date:** [October 3, 2014, 1:13pm UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/13 "2014-10-03T13:13:53Z")
The pack was initially owned and assembled by Matt Fix who then donated it to me. I sent it down to Randy Forester in Texas to be stripped and rebuilt. But after about 2 years with no progress and what were gonna be retardedly high costs given the nature of its condition I asked to have it shipped as is back home. Randy had already torn the pack apart to near nothingness. I figured with people like Mr.Low in the group, myself and others, we can start tackling the majority of stuff in house. Alex is doing a phenomenal job restoring the pack back to a proper usable shell. I couldn’t see trashing it, throwing it away. I also couldn’t consciously dump it on to someone else either. Not for what it was. ---
**Author:** ![Lowberg](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/l/46a35a/32.png) [@Lowberg](https://forum.gbfans.com/u/Lowberg)\ **Post date:** [October 7, 2014, 7:11pm UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/14 "2014-10-07T19:11:58Z")
Sorry about the broken links, from now on I’ll host on Imgur. All the main holes are pretty much filled, I trimmed off the unnecessary styrene “[motherboard](https://www.gbfans.com/wiki/equipment/proton-pack/motherboard)” section on the right side ![image](https://discdn.gbfans.com/original/3X/5/7/570fd6aa13750a86bdc27bf7c847df202542cf6b.jpeg) I re-built a “shelf” for the N filter to sit on for mounting. This will give it some extra support as well. ![image](https://discdn.gbfans.com/original/3X/a/4/a4b6451b73444ca975587f5ae3c602f5dc014750.jpeg) The webbing around the edges is going to be impossible to get rid of, I’ve been sanding it down gradually getting it all to sit as flat as possible and we’ll have to just work with it. ![image](https://discdn.gbfans.com/original/3X/a/d/ad120bd0ccc29976d1d900a439b86d8cf6eaf76a.jpeg) There’s some major gaps where the two shells attach, I’m going to tack the two halfs together on a few points with epoxy putty and then work on filling those gaps in with putty and bondo and blending it as smooth as possible. Re building this shell is the trickiest part, after it’s in acceptable condition it should be smoother sailing just attaching parts and such. Shooting for having the shell finished by the weekend. We tracked down a photo of the “original” build of this pack hahaha. As long as I can make it look nicer than this then mission accomplished: ![image](https://discdn.gbfans.com/original/3X/6/f/6fdb9b9f824673e2a398297a71f7839f644c06ef.jpeg) ---
**Author:** ![GreenSlimer\_2285-11](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/g/46a35a/32.png) [@GreenSlimer\_2285-11](https://forum.gbfans.com/u/GreenSlimer_2285-11)\ **Post date:** [October 9, 2014, 5:12pm UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/15 "2014-10-09T17:12:13Z")
It looked like it was drunk. ---
**Author:** ![Rabbit](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/r/919ad9/32.png) [@Rabbit](https://forum.gbfans.com/u/Rabbit)\ **Post date:** [October 10, 2014, 12:41am UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/16 "2014-10-10T00:41:07Z")
I feel like the problem with most vac-packs are that the buck they are formed from has all of the smaller details already in place i.e fins, [cyclotron](https://www.gbfans.com/wiki/equipment/proton-pack/cyclotron) windows, clippard spacers. Had it been stripped down more and it may have been a bit sharper looking. ---
**Author:** ![Lowberg](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/l/46a35a/32.png) [@Lowberg](https://forum.gbfans.com/u/Lowberg)\ **Post date:** [October 11, 2014, 7:47pm UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/17 "2014-10-11T19:47:51Z")
Began the task of joining the two shells, The “seams” where they overlap were all cut away and had huge gaps. Began by using epoxy putty from the inside and a little bit pressed in the seams to form a good bond ![image](http://i.imgur.com/gCFcBZJ.jpg) Then I used some bondo body filler to blend them together and with a lot of sanding and spot putty we got to here: ![image](http://i.imgur.com/65banl7.jpg) Still needs some more fine sanding and filling to get it right but it’s getting there. Just a real pain in the ass to sand in those tight spots ---
**Author:** ![Lowberg](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/l/46a35a/32.png) [@Lowberg](https://forum.gbfans.com/u/Lowberg)\ **Post date:** [October 17, 2014, 3:39am UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/18 "2014-10-17T03:39:46Z")
Just been finishing up the body work The bottom edge of this corner was GONE, and chewed up as seen here ![image](http://i.imgur.com/6ZtIf6b.jpg) Filled that with epoxy putty and sanded it back down straight ![image](http://i.imgur.com/F4spUUc.jpg) Also worked on the corners blending where the two halves meet ![image](http://i.imgur.com/s8202IF.jpg) Then the round corner behind the HGA wasn’t round at all, actually the corner wasn’t even there It was cut at a straight 45 degree angle before. ![image](http://i.imgur.com/u2jNVSm.jpg) So I fabricated the round corner out of styrene ![image](http://i.imgur.com/Gy2raj2.jpg) Added styrene plating ![image](http://i.imgur.com/lUW7jcf.jpg) ---
**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:** [October 17, 2014, 9:31am UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/19 "2014-10-17T09:31:08Z")
Its amazing watching this unfold. ---
**Author:** ![Grimmy\_GB](https://forum.gbfans.com/letter_avatar_proxy/v4/letter/g/dfb087/32.png) [@Grimmy\_GB](https://forum.gbfans.com/u/Grimmy_GB)\ **Post date:** [October 17, 2014, 4:25pm UTC](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025/20 "2014-10-17T16:25:05Z")
This is a load of work for a vacuform. But I can tell you one thing, it’s turning out jammin 0o [Next page](https://forum.gbfans.com/t/you-cant-polish-a-turd-but-im-gonna-try-vacuform-refurb/4025.md?page=2)