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Welshchris77's pack build


welshchris77
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Chris, I think Tony's idea with this line or ridge is that it is supposed to slide the face plate in to the box as soon as you've built it, so it stays put. Of course you will also have to attach it in some way, magnets or something similar. 

So I wouldn't recommend sanding that down. 

Too late I already sanded if off, oops!, think it will be ok though, one of the corners wasn't moulded to that line anyway so I needed to straighten things up a little, I can join the face plate at this line directly to the box I build, only thing that might be effected is the depth of the box, night have to increase it a bit to allow for the edge I sanded off.

 

343a3f15c5203a4867062591d6307978.jpgdbfb3b10eb6623524de40d3fe81d869b.jpg

 

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On 10/30/2019 at 10:17 PM, Marv said:

These are the parts I've managed to accumulate, was lucky and picked up a UP85 last week and my two replacement chemical bottles arrived yesterday, they are definitely a better fit.
The Sonix was my first part, otherwise this was going to be a nonstarter.

bits.jpg.ac2602c8ed30ec041521f5d77048b182.jpgbits2.jpg.5c8c8a05a74822ddba080e7b607493f5.jpg

Looks great John, good to see you got a siphon after, where did you get your chemical bottles from and what diameter are they?

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Here you go Chris if you ask seller they'll add more:https://www.ebay.co.uk/itm/1000mL-Widemouth-Dual-Cap-White-Plastic-Chemical-Storage-Case-Bottle-Container/382419368999?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m2749.l2649 Also put measurements you were after in the earlier post. 

 

 

Thanks John. I see you mentioned previously that the leather part is 75mm wide, I can construct my box depth 75mm to suit  

What way does the back panel work in relation to the box frame?, does it sit inside the frame or butt up against the back of the frame, ie equal to the outside dimensions of the box frame?

If that makes sense?

 

Also just to clarify, the outside dimensions of the built box is the same as the outside dimensions of the front face radio casting correct?

 

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  • 2 weeks later...

Testing out the position of the material braces and the support bars, have others positioned them in a similar way?.

I am starting to wonder if the original packs even had support bars?, they are useful to stabilize the pack and keep the seed trays in place for trooping but would the art department have gone to the trouble of fitting the bars or just found a way to attach the trays to the fabric braces

9f24d45d73dce2535dda563ef97d795b.jpg66f45a364ab5854c7bb0ef91f91f356b.jpg

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I think you're right about the original packs not having support bars. A friend has attached the trays to the fabric using zip ties. He even uses the pack for trooping and has reported that it is actually quite sturdy, no rattling. 

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7 hours ago, Hausi said:

I think you're right about the original packs not having support bars. A friend has attached the trays to the fabric using zip ties. He even uses the pack for trooping and has reported that it is actually quite sturdy, no rattling. 

Thanks Urs, I might try it without the bars and see how it holds up :) 

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I personally believe the original way to attach therapy’s to the backpack frame is closet what Urs already wrote.

I don’t have access to all my reference pictures atm but after studying all available pictures I came up with my personal theory that the trays were attached like this...

4743-F605-EFF5-47-AF-90-F7-71-E23305-B29

 

That way it would imho also explain a lot of these weird, uneven placed trays right next to the frame on the original backpacks.

I‘m unsure but if memory serves me right, I even found a picture which showed a small edge of the supporting plate in the right upper corner, or what looked to me like such a plate. That’s why I choose to leave mine that big.

Well, at least to me that makes sense...   :D

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8 hours ago, RoCKo said:

I personally believe the original way to attach therapy’s to the backpack frame is closet what Urs already wrote.

I don’t have access to all my reference pictures atm but after studying all available pictures I came up with my personal theory that the trays were attached like this...

4743-F605-EFF5-47-AF-90-F7-71-E23305-B29

 

That way it would imho also explain a lot of these weird, uneven placed trays right next to the frame on the original backpacks.

I‘m unsure but if memory serves me right, I even found a picture which showed a small edge of the supporting plate in the right upper corner, or what looked to me like such a plate. That’s why I choose to leave mine that big.

Well, at least to me that makes sense...   :D

That indeed is a possibility, I can also remember noticing some weird edges visible on some of the packs. They probably just tried different ways of attaching the trays on set... after the first ones started falling apart. I think the most accurate way of trooping would be to start the day of trooping with a wonderful pack and end it with something that has fallen to pieces:lol:

So always keep the gaffer tape at hand. 

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8 hours ago, RoCKo said:

I personally believe the original way to attach therapy’s to the backpack frame is closet what Urs already wrote.

I don’t have access to all my reference pictures atm but after studying all available pictures I came up with my personal theory that the trays were attached like this...

4743-F605-EFF5-47-AF-90-F7-71-E23305-B29

 

That way it would imho also explain a lot of these weird, uneven placed trays right next to the frame on the original backpacks.

I‘m unsure but if memory serves me right, I even found a picture which showed a small edge of the supporting plate in the right upper corner, or what looked to me like such a plate. That’s why I choose to leave mine that big.

Well, at least to me that makes sense...   :D

That's a white ABS sheet? Wouldn't it be easier to have a black one to start with?

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17 hours ago, RoCKo said:

I personally believe the original way to attach therapy’s to the backpack frame is closet what Urs already wrote.

I don’t have access to all my reference pictures atm but after studying all available pictures I came up with my personal theory that the trays were attached like this...

4743-F605-EFF5-47-AF-90-F7-71-E23305-B29

 

That way it would imho also explain a lot of these weird, uneven placed trays right next to the frame on the original backpacks.

I‘m unsure but if memory serves me right, I even found a picture which showed a small edge of the supporting plate in the right upper corner, or what looked to me like such a plate. That’s why I choose to leave mine that big.

Well, at least to me that makes sense...   :D

I like this idea, it is an interesting concept.

I may try a few different ideas with this before committing to anything permanent, thanks for you input Roger :duim:

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10 hours ago, Hausi said:

That's a white ABS sheet? Wouldn't it be easier to have a black one to start with?

Yeah, it would be easier and definitely not as visible as a big white sheet but i'm still pretty sure i have seen a white edge on some reference pictures from my library, so i decided to try this way first.

Unfortunatly i'm still in the building process so i haven't had the trays attached to really know how it will look.

Most of it should be covered by the frame anyway, at least that what i think it will look like...    :rolleyes:

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Tried out a few different things for the shoot gun shells including various sizes of plumbing pipe but nothing looked like the right diameter, eventually I came across some metal pipe in my shed that looked like it might work.

 

From the pictures I have seen of the originals they look to me to be some kind of electrical components, fuses or capacitors maybe.

To achieve this look I wrapped electrical tape around each end of the pipe then filled with car body filler and sanded the ends smooth .

 

After that I constructed a bracket from some scraps of abs plastic and build a box to make a silicone mould.

When the silicone mould was cured I started to cast copies in black polyurethane resin, I also made a jig to hold a machine screw in place while the resin cured.

 

I cut a support plate from 2mm black plasticard and bolted the shells throught the plate and seed trays adding an interior brace also, everything is very strong and sturdy and the shells do not move once the bolts are tightened.

 

I latter drilled a hole in each shell and glued in small pieces of wire then painted the wire black.

 

They may not be completely accurate but I think they look ok for now.

 

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So my pack is pretty much finished now and I am happy with how it turned out

 

Here is an update of what I did since I last posted:-

 

I shortened the bottles by cutting with a dremel and riveting back together.

 

I fabricated new panels for the frame from canvas using the one original I had as a template, painted them with Daler Rowney system 3 cadmium red acrylic, then oversprayed with auto satin black, finished by copying the internal metal brace pieces in aluminium.

 

Cut off the dial flush element of the Syphon and fabricated a bolt for attaching the bottle by threading a length of brass rod and silver soldering a flat brass disc to the end, I then used bolts and wing bolts to hold the various parts, I decided to keep part of the internal syphon mechanism as it looks cool, I had to back it with a black piece of plasticard to keep it steady.

 

Sprayed the original straps with satin black and re-attached.

 

I assembled everything using tiewraps, it was quite fidley feeding them through the holes, I started from the back strapping the radio, syphon and brexton to the top trays, for the exhausted I used copper wire as it was just easier to thread through, I then strapped these to the bottom trays, in some places i superglued patches as there was no anchor point for the tiewraps, finally strapped the bottom seed boxes to the material panels.

 

The mortor tube is screwed to the frame at the top, the bottom was a bit trickier, can't really see fron reference pics how it is attached there so I improvised by drilling two holes close together and tiewraping it losely to the frame to slow it to hang in the correct position.

For the radar dish I used a 5" sanding backing disc, took off the metal components and fabricated a plasticard disc to use as a reducer for the hole to keep it all on place.

 

Have since added a hose clamp to the exhaust part

 

The pack weighs in at around 4kg, not too heavy

 

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Looks great! Let's see some more pics, sides and top too. 
Pics added

I have been busy lately but when I get time I will take better pics outside under natural light with a decent camera, my phone camera is somewhat distorting the perspective and the lighting in very bright in my shed.

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Looks great Chris, how are the zip ties holding up? Looks pretty sturdy to me,

The exhaust port tube looks a little long but that should appear less obvious as soon as you have added the hose clamp.

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Excellent work, mate! I LOVE your attention to details!

That said I have one thing you might want to redo is the siphon attachment point for the bottle.

On the screenused pack it’s almost flat and doesn’t have the raised base if you know what I mean...

Here are some reference pictures...

F7887-A8-F-3054-4430-8183-6-D3-F0-CB79-A

B5-AB6-BFB-C77-A-4-A3-B-B83-F-9-F3254516

0-CFCBFF9-95-A2-433-D-A4-EC-D4-C1485-F60


I hope these pictures help...   :salute:

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