Ghostbusters Project: Finalising the Booster

To continue where I left off yesterday, I continued the work on the Booster on my Ghostbusters Proton pack.

I took the raw 3d print, sanded off the biggest irregularities and then covered it heavily in spray filler. Once cured, it was time to sand it off again…

Two rounds of spray filler and sanding off until it was smooth, then time to start painting. The key to paint with spray colours is to build it up in thin layers and let them dry in between.

Once the paint was dry enough (it also dries a LOT faster when you apply it in small layers), it was time to clear coat the booster.

Once dry, it was time to mount on the proton pack. The mounting was done fairly easily and quickly. In reality, I should do a weld line around the booster, but as I am planning to replace this (possibly) with an aluminium tube at some point, I have opted to not do this just yet. We’ll see. If so I have the weld line to build up with epoxy resin, and also to do the “ugly weld” between the booster and the Ion arm.

So far, so good.

One of my pet peeves when it comes to 3d printing is that many people unfortunately do not put in the effort of making their prints smooth. Some people wishes to keep the 3d print lines as a statement, which is fine, but many prop makers don’t use the tool to its full potential: which in my world means to use the 3d printer to save time when building the core item, and the time saved in construction can be put into finishing instead. If used like this, and you use smart methods when doing the finish, you will save time overall and still have a prop that looks great!

Last piece to do on the outside of the pack: paint the motherboard, do the ugly weld and (possibly) the weld around the booster tube, then time for the dressing of the pack, adding labels, routing all the little cables and stuff that makes it look great.

There is still a LOT to be done on the inside of the pack, not to mention the thrower that I’ve barely started with. My plan for the thrower is to 3d print mounting panels to be placed on the inside of the thrower to hold the electronics in place.

By | 2017-06-09T16:12:23+00:00 June 9th, 2017|Building, Ghostbusters, Ghostbusters Proton Pack|Comments Off on Ghostbusters Project: Finalising the Booster

Ghostbusters Project: Building a Booster

One of the few items I have left on my pack is the booster tube.
I sourced a few nearby stores for fitting tubes in PVC, but found none that were even near the proper diameter, so I decided to make my own. Let’s get that 3D printer to work!

Now, the print went over night and when I started it last night, I was tired and used the wrong settings, so it is all spotty and blobby, but the new one above is straight off the printer with no sanding using the correct settings!.

Here are all the parts:

The booster plug just fits inside the outermost part of the booster tube, and is fastened from the inside with an m3 bolt.

All parts of the tube are designed to be screwed together to help when gluing them. I use these brass inserts that I just head press into the plastic and i just love them!

They are simply pressed into the plastic with my soldering iron, so they are melted in place.

All three parts fit together, and all holes are already made into the design.

Apart from the annoying spots, this looks pretty ok!

Here is the new booster tube, printing as I write this, and will keep on printing for another 10 hours or so. It looks much better when printed with the correct settings!

Finally a few shots of the pack with all now painted and fastened parts, apart from the booster tube and frame, which are the last parts to be mounted on the pack.

By | 2017-06-08T23:23:56+00:00 June 8th, 2017|Building, Ghostbusters, Ghostbusters Proton Pack|Comments Off on Ghostbusters Project: Building a Booster

Ghostbusters Project: Modifying the Clippard

One of the features on both the proton pack and the thrower (the “gun” if you will) on the Ghostbusters costume from 1984, is a Clippard Valve. It is apparently used for something in the real world. In the Ghostbusters world, it is a thing that looks cool.

A while back, I 3d printed a copy of a clippard to keep on my proton pack to keep the weight down, and sitting right next to the real deal, it looks pretty good!

The twist knob still needs a little more work, but I’ve got a resin copy of that coming in, but what I’m devoting THIS post to, is modifying the original Clippard (The one that is supposed to go on the gun) to work as a volume controller for my proton pack.

After first opening the clippard and taking it apart, removing everything on the inside, I had to first saw off the round tab on the bottom  and drill a hole, allowing the cable to run through.

I also 3d designed a huge spacer/holder for the potentiometer that was to be placed inside the clippard.

I needed to cut down the pins on the potentiometer in order to make it fit properly, and once it was cut down and the wires were soldered, this what I was left with.

In the picture you can also see a spacer that I threaded and had screwed in place, and blue painters tape on the threads and rotary part of the potentiometer. You’ll see why shortly…

To make sure I had enough room for the solder joints, I drilled out the top of the inside of the Clippard with a stepper drill, just to give some more space. The enclosure will be held in place 6 mm further down where the inside diameter will match the 3d printed enclosure perfectly.

The potentiometer fit like a glove into my 3d printed enclosure.

Pushed down into the Clippard with the cable going out through the hole I drilled in the bottom:

When I started to put the clippard together, the thin axel of the potentiometer didn’t exactly look like the original… so I had to do something here. I took the original threaded part that was hooked up to the clippard and the rotary knob, and put it in my power drill with a metal blade to cut off a small piece.

It was still larger than the potentiometer on the inside, so a few turns with painters tape was just right to center the brass bit.

Finally, attaching the knob at the top again, and I now have a potentiometer for the volume built into my Thrower Clippard!

Can’t wait to actually fit this on my pack in the (hopefully) near future.

By | 2017-03-27T00:17:37+00:00 January 5th, 2017|3D Printing, Building, Costuming, Ghostbusters, Ghostbusters Proton Pack|Comments Off on Ghostbusters Project: Modifying the Clippard

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