SPent about an hour today working on my sons Proton pack for Halloween. Again it is out of foam just like mine, It will have some lights but not the proper kind, I will see what I have laying around, the plan is that this proton pack will cost under $30.00 to complete.
Foam is great stuff for a pack. Be sure to get all the little dress-up parts on there if you can. It makes the packs that much better.
Here's the 75% scale one I did for my son last year made from foam, wooden dowels and some styrene. When done it was just over 4 lbs with the thrower attached. I'm hoping to add sound in the next couple of weeks.
Also one suggestion is if you can find it try the dullcoat foam spray paint from testors (I got mine at Michaels). I used that on my sons and it evened the color out and really brought out the details.
Bwahaha. This is amazing man. I'm in the tail end of Proton Pack build for a friend, and seeing this made my day. It really looks awesome, and I can only imagine how thrilled your kid will be to have it. Can't wait to see how you finish it!
So I finished a smaller scale trap for my sons costume and made a PKE meter out of a hair brush also made him a radio and then using some fake leather I made some holsters and clips for his belt. He wore it to school on Friday for his halloween party and was not only a huge hit in the playground but he came first in their costume competition.