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459 Field Pack


TK-459
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I wanted to start posting a few pics of my pack in progress. I've been collecting and building parts for a while now, and its really starting to come together. I'll update as I finish it.

I'm using the alternate upper tank. For this, I found a conditioner bottle by Tre Semme. I cut a bit off the bottom and attached a piece of sintra. Still need to work on the cap area.

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I built the upper box out of some scrap styrene.

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The upper filter box is made from two PSP boxes and a layer of sintra on the face. I cut the inner edges with a razor, glued all the layers together, filled the gaps with epoxy and bondo, then finish sanded. I then took a section of a Fram air filter and seperated the folds a bit to spread it out with less peaks.

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I found my frame at a yard sale. The frame had many of the shapes I was looking for, but did need a lot of modification. I cut off a section from one side, shortened an area where two parts join, put in the needed bends, and cut out about 1 inch from the width (reconnected with wooden dowels and JB Stick Weld). Most of the bends crumpled up when I tried to do them, so I repaired them with JB Stick Weld and sanding.

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I bolted in Seth's boxes so that just a bit of the boxes past the frame, and also bolted them together at the middle so that the boxes hold as one unit. I them put strips of foam weatherstripping between the raised areas on the bottom to keep the pack from scratching against the armor a bit. Still have to paint the bolts and add parts, but at this point these are test fits.

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It's always difficult to film the colors, but for the blue sections I used Kilz Satin Supernal Blue as a base and Kilz Satin Calling Bird over most of it. Combined, it gives a painted weathering that I can't really capture with this camera.

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Here you can see the finished filter.

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I let some of my parts hang off the main boxes a bit. Radio Box details here.

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More to come.

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A few in-progress updates.

Tank Dish

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Vac adapter

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Still needs the larger coin shape on the lid

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Finished Stinger. I vacformed the taper piece that fits on the bottom.

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So far...Gotta finish a cap for the manifold among other things. I think I'm gonna trim the stinger a bit more too.

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More updates! I love working on this pack. I cut the top half of the PVC connecting the tubes for the manifold and then epoxied the flat surface to the cap. I had to vac the cap which came out decent. I also vacced over the desert cup to size it up a tad and get rid of the texture.

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Almost there...

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  • 2 weeks later...

Al....most...finished. Just a few details to go.

I'm going to have to replace my mortor tube with one of the ice tubes you guys are using. I tried to section a plastic flourescent tube around a 2" steel pipe by overlapping two pieces, but a few hours after removing the pipe and just as I finished assembling everything I started to notice stress fractures in the thin plastic. Oh well. I decided to put the top cap on the mortor tube to keep things out of there. I also have to get the straps on this thing and see how it feels.

I feel really good about how the pack came out. I'll really celebrate once I can actually put it on my back.

Thanks again for all the great resources here. The gallery and info really helped out.

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