[wm6929]

I would like to go ahead and start a thread documenting my progress building a Proton Pack using a well known Pep File.

I wanted to build a really clean and detailed pack using styrene or PVC board. I wanted to build use exsisting plans, readily available materials, and a little know how.

First, I scored some free 1/8 and 1/4 PVC boards from my old work. Alot.

Then I printed Stefan's plans, Sean's plans, and the thrower plans from Hprops. From there I started the Thrower. Just as I was humming along with the thrower, something hit the internets. Thats when Protoncharger posted his build thread.

Protoncharger posted a Pep file that he created from scratch. He worked a very long time on it and is very detailed and the most accessible that I have seen that would fit my means.

So with the files in hand, I decided that I was going to use the Pep files as TEMPLATES. Then I was going to transfer the TEMPLATES to PVC.

First, I started small, and printed out the smaller parts one section at a time. Once I printed the file, I cut the tabs off, and (if I used 1/8 board) compensated by removing 1/8 off the approriate sides.

[wm6929]

Cut two pieces for this section.



Top piece


Hopefully these are some what self-explanatory

[wm6929]

Assembled


x2 1/4 inch PVC for the trim ring


This is were, for some reason, I started slacking on documentation. But I should leave it on the Cyclotron. 100% scratch.
First I cut two disks with a 8 7/8 dia. On one of them I cut a inner dia. meter of 8 3/8. From there I cut a strip and wrapped it around the ring and disk. This created the pan. Then I stacked smaller diameter discs on top of that, coated the edge with bondo then routed it with a round over bit. Similar to the way Bigi71 did his.

[KCGhostbuster]

Looking good.

[Cole Funstuff]

Very nice! I love me some scratch builds.

[jessejames51]

pure awesomeness!

[ProtonCharger]

ive been excited about seeing where this is going since you talked with me about it the first time! it's looking awesome!

[wm6929]

Heres a couple more photos.

[wm6929]

This is where it sits today, after a two month hiatus:

[wm6929]

Hiatus over

Started working on the pack again, and this part sucks.
Bondo, sand, bondo, sand, add parts, bondo, sand, add primer, bondo, sand,.........

Then you get this:

[gbrob]

Wow!

[wm6929]

Here is some more pics, with the powercell. Its not attached just yet, I have some more work to do to it, before it gets glued and bolted on.

[Charlie Richter]

Guybrush Approves!

This build looks totally awesome!

[AJ Quick]

That really is incredible for the method you are using! Heck it would be incredible for any method!

[Filandrius]

Holy shit this looks great. Keep going bro, this is one of the best looking scratch build I've ever seen.

[Jon Wallace]

Do you have an estimate of how much pvc you have used so far? I'm about to start building a pack using pvc sheets and I don't know how much to get. I'd hate to buy too much, especially since the price for the sheets sky-rocket the bigger they get.

[ProtonCharger]

that thing we talked about the other night works like sweet delicious butter.

[wm6929]

2 sheets
36 x 24 inches
.125 thickness

1 sheet
22 x 28
.250

I got a bunch of this stuff from my old work, they were going to throw it away.
Once upon a time, someone here said they bought direct from Evergreen Plastics instead of going through their local hobby shop. You could try the same. Fast Signs will also sell you some PVC sign material. I got scraps from them and I used must of it on my original thrower.

[Jon Wallace]

this is great news, i was thinking i'd have to buy a lot more than that.

[wm6929]

that thing we talked about the other night works like sweet delicious butter.

There's a joke in there somewhere.

[nick-a-tron]

Wow great work! You have skills my friend.

[loly2kn2]

Nice pack!

Lawrence

[wm6929]

Thanks for the comments.
I am open to suggestions as well.

I have been working on the pack on and off for the past week, mostly the little bits. I am going to try and work on it tonight and post progress on 10-03-11.

[wm6929]

I promise I have not been completely lazy.
I have been scratch building all of the greebles. By the time I start one, I get bored and start another. I have now decided that I am not going to start another one until I am 100% with all of them.


Discs


Still needs some work



PPD, still need to cut it to length, drilled, and studs glued in.


Injectors. Welds don't match. Did that on purpose, now I am not so sure about it. Still needs the mounting plate and studs glued in.

[wm6929]

MOAR


needs to be fitted and sanded.


Top plate needs to have the tube installed and small fake welds


Ion cap needs to be fitted.


HGA and N-Filter. Need to re-size my templates for 2.825.

[wm6929]

BOOSTER TUBE!



Gotta get the nut inserts installed for the mounting points and booster frame

and for something completely different, thanks to Adam:



its a bit rough, I did it in haste. Right now I have it on the back burner.

Todays lesson: Habor Freight drill bits suck. They can bend with the slightest touch.

[wm6929]

Hold ON. I left the best for last.
Again, I am not 100% satisfied with it. I will have to work on it a bit more.

[MRblahface]

HOW DID YOU MAKE THAT ION KNOB?

[wm6929]

HOW DID YOU MAKE THAT ION KNOB?

Well.....I'll tell ya.

The Shock mount is made from Styrene. I did not want to use fender washers, because I thought it would be too heavy.

First I used .060 styrene and .080 styrene. Then I cut the circles with a 1 3/8 hole saw and a 1 5/8 saw.
After you cut them out, respectively you are left with 1 1/4 and 1 1/2 styrene washers.

Since the drill bit is the same size for both sizes of washers, I was able to use it to glue them together and align them at the same time.

[GeistKopf]

This is GORGEOUS!

I'm currently making a styrene Bumper for my Foamcore scratch build, but I may have to steal your ion knob idea too!

Great work.