The first fiberglass shells from the 2 part mold...











Thin wall PVC pipes will be laid in the front and back barrels and joined with an awesome adhesive called Weld-On 45 by IPS (more on that later) and the box section will be joined together with a PVC lip and secured with the same adhesive. Once all joined together, the seams will be filled and sanded. Plenty of room for all switches and electronics. Completely accessible by unscrewing a bottom plate, just like the GB2 screen used guns. VERY lightweight! and durable.

Why is the seam line like this?

The seam line should follow anywhere there is a smooth surface. It's best to avoid running over ridges and details, basically anything that would require extensive sculpting afterwards. It's much easier to fill and blend a smooth surface.

More later...

Fullers Earth is a very fine natural clay powder that the movie industry uses to create dusty and aged environments on sets, costumes and props. I used it on my proton pack to give it that dusty "Planet Hollywood" look.

I put some Fullers Earth in an old sock and used it like a powder puff all over the shell, then brushed it around with a dry paint brush...











It can be completely cleaned away with a damp cloth or be made permanent by lightly misting a clear flat spray. Since my pack just hangs on a wall, I'm good with it not being sealed but if you're a convention goer and want that dusty look to remain intact, then sealing it is a must.

If your pack is painted Semi Gloss black and you want to subdue the newness of the paint without it looking like it's been sitting in a warehouse for 20 years, cover your pack with Fullers Earth then lightly brush it all away. Avoid wiping it completely away. You'll be surprised at how well it brings out the details.

Fullers Earth can be purchased at Todd's Costumes for $3.99 per 5 oz. bottle.

One of the first few shells pulled from the mold with slight paint weathering, red Mag-light lenses in the cyclotron, Rosco blue lighting gel in the powercell, and temporary self adhesive paper labels...







White gelcoat with 3 thin layers of glass matt. Average thickness is around 1/8" with thicker areas where added strength is needed.

Painted inside and out with Semi-Gloss Black spray paint.