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Ghostbusters Project: Mounting the pack

Since I received my motherboard, I could start working on attaching the motherboard to the frame, and the shell to the motherboard.

One of the first things I simply had to try, was to fit the speakers on to my laser cut grille, and they matched up perfectly!

Next up was drilling the holes into the Alice Frame, which was a lot harder than I thought, but it worked out fine.

Once the motherboard was attached, I started attaching the L-brackets that holds the shell to the motherboard.

I used very strong magnets to hold them in place while I gently pushed then around with the shell to get where I wanted them, then drilled through and riveted from the back, as per the original packs. When they had been placed, I taped them while I carefully marked the positions for them with a sharpie.

Note that I let the L-bracket underneath the mount point for the thrower lie down, in order to make proper space inside for the metal reinforcements I will put inside.

Of course, not all of them were a perfect match, as I don’t have a proper work bench or drill press. One of them moved around a bit, but with a little filing, it fit just fine.

With the pack clamped down on top of the brackets, I drilled through the shell (going backwards first) with a 3mm drill, then continued in into the L bracket to get the hole at the precise correct place.

Once the guiding hole was done, I drilled upp to 5mm on the brackets..

.. before I hand tapped them to 1/8″.

Tapping is hard work, and with aluminium, it is important to lubricate (I used isopropanol) and go forward a turn, then back half a turn, lubricate, and repeat.

Just look at these lovely blue Pyle speakers. They will make my pack loud!

Once all holes were tapped, I screwed the motherboard in to place..

And had my (bored) fiancée take the obligatory first pictures of me wearing my work in progress:

Let me know what you think. I think it fits well, and looks like it has a good height on me.

One thing that bothers me though, is I think my shell is a bit wonky, turns out that there is a gap…

With a little mild pressure, it closes nicely, however. I’m not sure how to solve this. I think there might be a place on my shell that needs a bit of filing, but I might also make some bracket that this can hook in to from the inside. We’ll see.

I am not too worried, though.

Finally, as a closer, I also received these:

By | 2017-05-24T22:41:28+00:00 May 24th, 2017|Building, Ghostbusters, Ghostbusters Proton Pack|Comments Off on Ghostbusters Project: Mounting the pack

Ghostbusters Project: Metalworks

Things have been a bit slow on this project for some time. Main reason is that I’ve been waiting for some key parts that prevents me from going further.

Last week, One of those items arrived.

The all aluminium proton gun by CPU64, and it is a beauty!

For some reason, I just had to start assembling it, filed the opening for the bar graph just large enough for it to fit, added some switches and buttons and the Clippard valve..

I lacked a tap for 1/8 inch imperial holes, so I could not finish the top button that should be there.

Also, I have only marked the location for the side knob and the heatsink. Still need to figure out the position of the gun rack to go below.

Hat light extends a fair bit below the wing, need to check out ref pics for these if I should cut it shorter or not. Most likely not.

Right now, a lot of wires just shaking lose inside, connected to nothing. I also need to make sure that the wires are not in the way for the pop out mechanism Chris (CPU64) has made. Another thing I need to figure out is how to attach the acrylic tip to the metal tube inside. I am thinking E-6000 or possibly hot glue.

As soon as I get the tap, I can finish off 99% of my proton gun. There is still some work to do, but mainly mounting electronics and rumble pack. I might 3d print some holders for things inside, or use the wall where the heat sink should be placed for getting a few screws for mounting things inside the gun itself.

Another thing I have been waiting for just got picked up by a friend of mine and is being delivered on Monday: Behold! My laser cut motherboard, complete with speaker holes!

This one is a bit scary as it was drawn and designed purely in CAD and should fit my Nick-a-tron shell, in theory, but I won’t know until I’ve actually tried.

I chose not to add any holes for rivets at this point, for obvious reasons 😉

(I just love how the mother board is first: upside down, and on the wrong side up. It’s almost difficult to place it more wrong =)

By | 2017-05-20T23:56:00+00:00 May 20th, 2017|Building, Ghostbusters, Ghostbusters Proton Pack|Comments Off on Ghostbusters Project: Metalworks

Ghostbusters Project: Attaching the N-filter

There comes a time in a build project where you just have to commit. To me, that day was today.

I had previously cut up the aluminium N-filter to match the curvature of the shell (fairly well), and today was the day when I decided to really fix it in to place.

I had decided, however, to add a smoke machine and some lightning inside this part, so I needed to make it accessible. The only way of doing this, would be to either have it bolted on somehow, or cut open the shell. I opted for the second option.

I marked the outline of the n-filter with a marker (on to painters tape, as I had already painted the bulk of the shell, I then went on with drawing a line offset 5-6 mm inside the outline, and used this as an outline for the hole I was going to cut up.
I didn’t want to just start cutting with my dremel as I have had “accidents” with the cutting wheel before, so I opted for something more safe. Drilling holes. A lot of them

Once I had drilled holes all around, and in some places, used my power drill as a mill, this is what I was left with. A big gaping ugly hole. It did however proved ample access from the inside:

In comes the rotary tool with a sanding extension to clean the jagged edges up nicely. I did touch up some of the cutouts on my N-filter as well, as I had moved it slightly from the originally planed position.

In order to fasten the metal N-filter to the fibre glass shell, I used a two-component epoxy putty. The drawback of this, is that it is fairly fast curing, so I didn’t have time to pause for pictures while doing this.

I first rolled a long snake of the putty once I’ve worked the hardener into the material, and pushed right inside the outline of where the N-filter would go, and then pushed the N-filter (hard) in to place, squishing the putty down. I then removed excess material, and worked up a new bunch of epoxy putty, making snakes again, and this time pushed in the material in the joint between the fibre glass shell and the aluminium filter. Using the wooden end of a fine paintbrush, rubber gloves and pure isopropanol, I smoothed the edges out and cleaned off excess material.

The isopropanol I have in my workspace is fairly strong, 99.5%, so in addition to the gently rubbing to smooth the putty out, I removed some paint at the same time.

After I was happy with the putty (it took me 3 rounds of adding and smoothing), I let it sit for 10 minutes (I did say it was fast curing) and then gently painted over the joint with normal black paint.

I figured that if the filter was attached to the cyclotron, which was texturized, and welded in place, the paint which was added would not have been texturized. It turned out just great.

Here’s a picture from the inside:

I have since reinforced the joint slightly from the inside, and removed excess putty with an exacto knife. Next session, I will grind the opening inside to perfectly match the N-filter, then reinforce some more, and start working on the drop-in insert that I am building for the light and smoke machine.

As a final teaser, here are some of the things that dropped in the past week:

The crank knob is the real thing. Just the wrong colour. Will need to trade or paint it. We’ll see.

By | 2017-05-02T09:01:03+00:00 May 2nd, 2017|Building, Costuming, Ghostbusters, Ghostbusters Proton Pack|Comments Off on Ghostbusters Project: Attaching the N-filter

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