First GB1 Proton Pack - Pepakura Completed !!!!!

Re: First GB1 Proton Pack - Pepakura

Alright, did a little more bondo sealer work on the pack just cause I'm very particular how I want it to look, but baring any accidental nicks or issues i find as I add more pieces then I am done and moving onto other things(spent a ot of time on the ribs and getting them sealed and smoothed).

I've cut the tubing for the booster tube and drilled the hols in the back where i will be attaching it to the pack(later update with pics once i do more with it)

The last two nights I've been working on the injector tubes that go under the power cell. From JeeBee25's thread I got a list of parts I needed and followed how he assembled his with a few minor variations.(I did not have access to the industrial hot glue he used)

Assembled the two adapter that go into each pipe and then cut it to length, using the uncut side as the bottom and the cut side where the adapters will go and sit up against a plate. I set the adapters inside and matched up the thread of the bolt to the length i needed to lock it down inside the pack, then used some hot glue inside to hold them in place. Once cooled I pouring in epoxy until it covered the whole area and mixed it up inside the tube. After the epoxy set on both sides of each tube, i lined them up together and applied hot glue in the middle of each side to hold them in place. The I traced out what would be my caps for the end of the pipe as well as the plate that it sits on underneath the power cell. Matched up the bolts to the plate and drilled my holes, then used the plate as a guide to drill underneath the power cell. This is what i had before continuing to the next step.
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Next I mixed up a small batch of epoxy and slid the plate onto the bolts, spread the epoxy on both the plate and the pipes and brought them together. I used the nuts for inside the pack to hold the plate against the pipe as the epoxy set(just finger tight). For the caps i put a extra piece on the inside for when I attached my hose barb and then epoxied the caps on. I didn't have any hose barbs to use that matched the clippard ones so instead I found a 1/8 OD splicer at home depot instead. After i drilled the holes and shaved off the barb at the end i would be inserting into the caps, i dripped in some epoxy and pushed the barbs in place. Here is the end of day 1 with the injector tube.
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Last night I finished up with the addition of a line of epoxy in the middle of the injector tube where i had hot glue for extra hold, and applied the fake welding to the caps and plate.
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and finally a quick placement to see how it looks
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Tonight I plan on working on plating that goes on the synchgen.
 
Re: First GB1 Proton Pack - Pepakura

Well I got a lot done this week, it might not seem like much but I was able to accomplish a lot. First I added the plating to the synch gen, which took the longest due to adding each plate one at at time with epoxy and clamping it down while it set. While that was in progress I built my beam line and filler tubes out of 1" pvc, some 1/8"styrene for the top and bottom caps, a bolt on the bottom for attaching to the pack, and added some epoxy putty to the seams and sanding them smooth( I'll have pictures of those tomorrow). I also did the hose receiving tube that sits in the middle of the crank gen.

With the plating I also added the injector box, which was difficult to do since during my building of it, the styrene warped a bit. So i covered the whole thing in epoxy putty and then sanded it till it was even and smooth before attaching it to the pack. I drilled several holes for parts while the plating process proceeded, patched some trouble spots, and cut out some discs for the synch gen and a test lens cover for the cyclotron.

I'll be picking it back up again tomorrow finishing the lens covers and the clippard disc and hose disc.
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Re: First GB1 Proton Pack - Pepakura

Got a little bit more work done this week with the pack. Once again though I forgot to take picture of the beam line and filler tube, but will take care of that tonight. So here is the weeks update:
-Cut out a 1/8" styrene disc for the bottom of the clippard disc on the synch gen and glue both pieces in place. Drilled holes for the clippard screws
-Glued on the lenses for the cyclotron
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-Test painted a smc elbow for the tubing to give it a more accurate coloring than the white grey it comes as default.
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-Assembled the hose tubing port for the synch gen and HGA
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-Hose Port for the Synch gen is 1" pvc glued to a 1/8" styrene disc. I used a 2x1/4" bolt in the center to later attach it to the top of the synch gen.
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-HGA consists of a 2" PVC with a 1/8" styrene cap, mdf plug at the bottom with bolts to hold it to the pack, 1/4"x1.5" fender washer in the middle, and fake welding
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With luck I will work on the N-filter tonight and then the bumper before I cut out the motherboard. I want to have all my holes drilled and parts placement tested before I start painting. Don't want and shattering or mistakes to happen
 
Re: First GB1 Proton Pack - Pepakura

After struggling with the hole pattern for the N-filter I finally finished building it. Attaching it to the pack also came with a challenge since there was a significant gap on each side, making it look out of place. In order to correct this I secured the filter on place and then used epoxy putty to fill the gaps and build up bigger pieces. So after drying and a layer of primer, this is where the pack sits
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I also took all the other parts and gave them about two light coats of primer
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Whats left for the pack before painting can proceed is to cut the hole for the tube that will go to the thrower and work on the bumper and bellows creation
 
Re: First GB1 Proton Pack - Pepakura

Well I felt squirrelly last night and gave the pack and the parts a coating of aluminum. Later on this will give a scratched weathered look to the pack
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I also cut out the motherboard out of 3/16 hardboard since 1/8" wasn't available. I have to wait for the mounting hardware to come in the mail so for now I have to set it aside.
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Need to make a store run tonight for some more grey primer for the thrower and then to radio shack for a dial for the crank knob for the crank generator. Also have to clean my work area tonight

NOTE: It must have been the heat or from crazyness but I'm going to redo the motherboard tonight because in the movie it is one straight piece underneath the ribs.....I will use the one i have cut already to plan my electronics before drilling anything into the good motherboard
 
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Re: First GB1 Proton Pack - Pepakura

Well last night I re-cut the motherboard and applied a coat of black paint to the pack and parts(minus one for a special paint job). Everything turned out great. Once it dries I will have the flip the parts over and spray again as well as any touch ups on the pack, but right now I'm getting close to attaching everything together
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Re: First GB1 Proton Pack - Pepakura

This is coming along really nicely.

You must have a real sense of pride when you look at your handy work ?
Nothing quite like making something yourself.

Great job, keep it up.
 
Re: First GB1 Proton Pack - Pepakura

This is coming along really nicely.

You must have a real sense of pride when you look at your handy work ?
Nothing quite like making something yourself.

Great job, keep it up.

Thanks:)!

I was skeptical when i started cause I have never done something quite like this before, it has been a learning experience with things I have never done before and in not being too critical. Alan said it best when he said adding the black to the pack was like a milestone in the build. I've very surprised with how well this has turned out so far and I'm going to finish strong! If I'm efficient enough I will hopefully have this done before the end of August for the Cincinnati Comic con.

I'm very glad I decided to build this myself, I don't think I would have been happy with it any other way.
 
Re: First GB1 Proton Pack - Pepakura

I'm very glad I decided to build this myself, I don't think I would have been happy with it any other way.

Yeah, there's nothing like looking at a finished prop of this scale and saying "I built this from a ream of card stock, some PVC pipes and shear will." I hope to never have occasion to git rid of my Pep pack.

On another note! You are truly rocking this build my friend!
 
Re: First GB1 Proton Pack - Pepakura

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Started attaching things to the pack. Got some progress, unfortunately I lost the ppd tube. It was a little too big and would have been pressed up against the beam line so I decided to shorten it, and well it cracked so I'm going to have to make a new one. No big deal I can still attach everything else in the mean time.
 
Re: First GB1 Proton Pack - Pepakura

Man, inspiring project. Build looks great.
Awesome, thanks so much:)

Tonight's progress:
homemade Bellows from fender washers and a 4" carriage bolt that will be cut to size once fitted with the bumper
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Added some more hoses and attached the V-hook for the thrower(which once the pack is finished I will move on to next)
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I also have the new ppd tube put together. Tomorrow it will need some rough sanding and a hole drilled for the hose before I send it off for paint, which I will throw the thrower parts in as well so no time is wasted.
 
Re: First GB1 Proton Pack - Pepakura

Did a little bit more tonight....looks so close to being done, but there is still so much left to do
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Started priming some of the thrower parts
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Re: First GB1 Proton Pack - Pepakura

Well I've reached the point of the 1st part of the pack where I have to stop. The next step is mounting it to the motherboard but the bracket haven't arrived yet and I don't want to mess with anything in the mean time
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While I wait, the final coat of paint dried on the thrower
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I was up till 4 this morning attaching parts, fixing stupid mistakes, and wiring things in place. I would have pictures of that but I gave up and when to bed. Hopefully after I fix some oopsies I will have them for you all later.
 
Re: First GB1 Proton Pack - Pepakura

Love this old movie. You have a wonderful project. Keep going.

Awesome, Thank you!

I present to you the past 2 nights(till 4am) work.........
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Minus Decals/stickers the thrower is done. The light kit is installed and ready to go and I just need to feed the cables into the splitless loom and secure that in place before plugging it into the pack

I was so happy with my work and proud I overcame a lot of my mistakes I tossed up a preview video. Now it is 4 am so I couldn't talk too loud and using a iphone to take it left me with little room to show off a lot of its features. I need to swap the bar graph animation on start up but other than that I can call this part of the pack done
 
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Re: First GB1 Proton Pack - Pepakura

Why i wait for my brackets to come in the mail, I'm kind of at a stand still for what I can get done. I know I have a little less than a month to finish but waiting on a part just to continue is driving me nuts especially when it was ordered 2 weeks ago.

Anyway here is some progress last night. Added a plate to the power cell that will hold the lights and circuit board. For the cyclotron lights I used metal condiment cup i found at the grocery store, drilled holes to match the LED size, and then glued them in place.

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Hopefully the brackets come today so I can work on mounting the pack and then go into finishing up with the electrical but if not I will find something to keep me busy
 
Re: First GB1 Proton Pack - Pepakura

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Thrower is now attached and most of the electronics have been installed. The motherboard has the L-brackets attached, speakers are in place and pattern drilled out for the flow of sound(thx Alan), and working on positioning the Alice frame.

There is one issue that I have run into and that is the limit of space in the pack.....unfortunately the sound/light kit needs an amp to get the sounds to stereo and the amp doesn't fit really anywhere in the pack so I will need to think of a place to put it. If all goes well tonight I hope tonight I can get more down and maybe finish within the week
 
Re: First GB1 Proton Pack - Pepakura

This is one of those builds that look so good, & you see the skill of the builder, & you think," Wow...I bet I could do that !!". Then you go out & buy materials & realize,"...oh yeah....I'm not that talented!":facepalm

Great build though. I can't wait to see a full-on working video.
 
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