Return of the Jedi: Proton Grenade (Bunker Buster) - Scratch Build

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zenx13

Member
Well - I have 6 client orders to fill, a large commission for a friend to complete and about 6 unfinished projects of my own to work on - so...

A good time to start another personal project?


I have had the Star Wars - Return of the Jedi: Proton Grenade (Endor Bunker Buster) on my mind lately. I was at the dollar store getting supplies today when I saw a plastic container that was the perfect size.

I fashioned the beveled ring (rough cut) tonight and now the project is underway! This endeavour will be like my others - scratch built (no 3d printing) with the use of "found" objects like the container below. I will try to sneak time in between everything else going on so please bear with me.

Cheers!
/sean

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zenx13

Member
A little more work on the Proton Grenade today:

Sanded the bevelled base and applied Mod Podge to give it some strength.

Printed out a diagram of the top area and transferred it to the prop using the "tried and true" carbon paper method:

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Next was to drill a bunch of guide holes to be able to remove the pieces:

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I used a Dremel with a number of different bits to remove the pieces:

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Next was to create the recesses out of my fabulous Pink Foam! I mixed up some "DIY" filler (wood glue and baking soda) and filled in the gaps:

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I am really enjoying this project and look forward to the next stage!

Cheers!
/sean
 

zenx13

Member
The inside housing for the ignition Switch was made from a thick cardboard tube and some heavy cardstock. The holes are essential for the main rod to pass through and will be used for all the mechanics.

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zenx13

Member
Lighting test for the 2 LED lights to be installed - happy with this set-up and I think the blinking lights will look really impressive.


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zenx13

Member
Testing the magnets on the bottom of the Proton Grenade - I think this may work but will depend on the weight of the inner components I still need to make.

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Here is a quick demo:

 

zenx13

Member
This next part has taken a considerable amount of thinking and planning.

I want my Proton Grenade to click and light up when the ignition switch is turned (OddViking has done something similar to what I was thinking).

I have constructed this housing to hold the internal components - it allows me to build all the internal items outside of the main housing making it easier to construct:

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Trying a dry fitting to see if everything holds together:

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Now I can move onto the internal components - should be interesting!
 

13doctorwho

Sr Member
RPF PREMIUM MEMBER
Great work!! I love to see these kind of scratch builds... especially with low cost materials. That kind of work really makes me proud. It really does look great.
 

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zenx13

Member
I even like the clear shell in this interim stage, nice progress so far!
Thanks - I agree! I thought it would be interesting to keep it un-primed / painted for as long as I can so the inner workings can be seen. I appreciate the support!
 

zenx13

Member
Haven't had much time to work on this but finally got to it yesterday and it went really well!

I don’t know much about electronics so I found it easier to make my own circuit board from the breadboard test. I am sure there are far better ways of doing this but this solution worked for me.

Here is a quick video showing the new circuit board for the flashing LED lights:

 

zenx13

Member
I installed the new circuit board onto the interior housing and dry-fit the LED lights. Really pleased with the results! The blinking lights look great!


Here is a close up of my "janky" circuit board installed:

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And here is the project to date:

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Next steps are to make a switch (rotating the rod) and a smaller battery pack than the test one I am using here!
 

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zenx13

Member
Creation of the battery compartment to hold a adjusted LED Tea Light battery structure:

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Development of a twisting, switch mechanism to turn on the lights:

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Video of the switch testing:

 

zenx13

Member
Development of the inner switch / rocker assembly - this item has wood on the top and bottom to fasten it securely to the main shaft / rod:

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Finished item:

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Tapping the backing plate for the "clicker" mechanism:

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Here is what the "clicker" mechanism looks like once assembled:

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All the internal mechanisms have been installed and completed - a quick video testing the full component:

 

zenx13

Member
Development of the side vents:

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I used HVAC Aluminum Foil Tape to provide the illusion the piece is made from metal.

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Gluing the pieces together - can't have enough clamps!

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And the finished part:

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I am really happy this this part and feel it has a good metal feel - some weathering later on and it should be good for the replica prop.

A tough part of being a maker is successfully completing a part and then having to do it again as the prop has the same part in multiple locations!
 

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