First of all:
- please excuse my bad english
- it's my first Proton Pack i'm building, so please be gentle when it comes to details
- initially it was just a Halloween project, but now i'm hooked with the GB Lifestyle (reading the Forum and the whole page makes you kind of addicted )
- the following pictures were taken during the last few months
it all started when i was young and saw the movies... "I wanna have one of those packs and hunt some ghosts!" Over 20 Years later when the Coivd pandemic startet, i decide to realise my Childhood dream and make something cool for Halloween. (Halloween gets more and more popular in Switzerland)
I asked 2 friends of mine if they would join me going "on patrol" this Halloween in Zürich to entertain the people And yes they do! So i knew i have to make 3 Packs for the guys. And two Traps (one as a hero prop and one that is smoking). And a PKE meter. And the Uniforms and and and....
It was end of march as i startet ordering the electronic parts and all the other stuff and i thought i'll have plenty of time and now it's allready October
that been said, lets jump into it
Making the Forms
So i had to make 3 packs. And i didn't want to build every part 3 times from beginning. So i decided to make every part of plywood and vacuform the parts needed with polystyrene. So i 'm able to safe some time.
Lets start with the Synch Generator/ Spacer:
Get some wood on the Lathe to make the disks for the upper part:
after some glueing and sanding, i got the synch generator finished.
NOTE: i don't have any other pics making the other Forms! but you can imagine that building the other Parts aren't any different
Building the Vacuformer
To get the 2mm Polystyrene sheets into form, i need a vacuumtable, a source of heat and a frame to clamp the styrene sheets into it. I got some steele angled profiles from the local hardware store to build the frame. The upper and the lower part are held together with hinges at the back. To clamp the sheets securely into place the frame is held closed with two screws in the front. (not shown here)
The table is build with an 1inch sheet of plywood. I had to drill 144 holes into the wood to make sure the vacuum will suck the styrene firmly to the forms.
Here the lower side is shown. The small blocks in the middel will prevent the top plate to bend inwards during the forming process. I don't have a picture from the lower plywood sheet. It only has hole in it to attach the vacuum cleaner
To even heat the styrene, i had to build an 'oven' where i can place the frame on top of it. So i got some 8mm plywood, made a box (around 2feet high), isolated it with tinfoil (to prevent the wood from catching fire) and placed two 1200w bathroom heater underneath it:
Now lets give it a try! I clamped a sheet of styrene into the frame, placed it over the heater, waited a few minutes until the sheets were hanging through, turned the vac on, pressed the frame over the form on the vacuumtable aaaaand:
I was impressed how detailed the result was Clean and crisp lines were formed. the same thing with the cyclotron:
The most tricky part was to get the forms out of the mold It can happen that the styrene molds can break while getting them off. But theres nothing what glue can't fix *wink*
So after that sucessfull test i continued to make the other parts, like the Booster / EDA. Here you can see that the corners won't sit flush to the form. So those must bee removed with a rotary tool later on
After a few evenings in the shop i had most of the parts together:
i reinforced the bigger parts with epoxy and fibreglss mats to stiffen it.
meanwhile the 3D printer was doing its things so i could start to glue the parts together:
gave it a coat of primer:
and got the can of paint out *wink*
I think it is not that bad (yes there is a neutrino wand in the picture, but more about that later on )
Note: This was just the first Pack, i didn't start with the other two packs because i wanted to get some 'experience' during the buildingprocess. So i know what i can do better when assembling the other two packs
Thats it for now, more to come