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

[zenx13]

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

 

[zenx13]

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:

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

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

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:

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

Cheers!
/sean

 

[zenx13]

Some more work completed - this session was on the ignition switch housing. Using my old jewelry skills to cut out the inserts.

 

[zenx13]

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.

 

[zenx13]

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.

 

[zenx13]

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.

Here is a quick demo:

 

[zenx13]

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:

Trying a dry fitting to see if everything holds together:

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

 

[13doctorwho]

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.

 

[James Kenobi 1138]

Looks great so far !

 

[mrwax]

I even like the clear shell in this interim stage, nice progress so far!

 

[zenx13]

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.

Thanks for the kind words - it is a really fun project and I am a big fan of scratch builds. I am also working on some Hoth Macrobinoculars in the same fashion if you are interested.

 

[zenx13]

Looks great so far !

Thanks James - I just wish there were more hours in the day!

 

[zenx13]

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]

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]

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:

And here is the project to date:

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

 

[zenx13]

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

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

Video of the switch testing:

 

[zenx13]

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:

Finished item:

Tapping the backing plate for the "clicker" mechanism:

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

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

 

[zenx13]

Development of the side vents:

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

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

And the finished part:

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!