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pandatrooper

Pandatrooper's Pack build

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Just thought I’d start posting up the progress of my backpack build. It’s based on the “Move Along” / pack #3, as the orange TD in the Cantina is wearing it and I have since identified that he is the “Stop that ship” trooper in this thread here:

http://forum.mepd.net/index.php?showtopic=6769

That being said, here’s what I’m using for my backpack:

PVC pipe frame

Custom sewn straps / padding

Crashmann seed trays, mushrooms, mortar tube, panel, exhaust port

Radio shack tool box

Tupperware lid radar dish

Grand and Toy (office supply) screen wipes bottles *I like the “straight” shape of them

Waiting for the new Crashmann radio faceplate / knobs

Gordonator siphon / cistern

While I was waiting for the Crashmann parts to arrive, I already built a PVC frame. It’s been sanded and glued together, then primered and painted with Krylon primer and Satin black.

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I used ¾ inch and ½ inch aluminum bars for supporting the trays. I will rivet them to the pack frame. I’m trying to save as much weight as possible, so I’m using 1/8 inch rivets where I can as opposed to nuts and bolts and washers.

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I have reinforced the areas where the bars will attach to the inner trays, by gluing in 2mm ABS plastic. I will rivet the bars to the frame, then rivet the trays to the bars.

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I trimmed the seed trays and sanded them, then painted them with Krylon primer and Satin black as well. I used Rustoleum Satin Slate blue for the lower trays.

Test fitted the trays, everything is lining up nicely.

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Underside of the exhaust port, base and little black triangles. I used some PVC pipe I had at home, which was a thinner schedule than the Crashmann kit ones, it was about half the weight (I know it’s not a lot, but any weight I can shave off – the better). I hot glued the PVC pipe into place.

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Exhaust port assembly completed (will add the black zip tie later)

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Exhaust port, mushrooms and toolbox before painting. I bonded over the holes in the tool box.

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Exhaust port painted

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Wipes bottles and stinger before painting

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After painting. I haven’t painted the cap of the stinger yet as I am waiting for some parts to complete it.

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Test placement of upper tray parts, with painted toolbox, mushroom, wipes bottle and exhaust port.

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Next steps: custom shoulder straps, modding the stinger, and modding / mounting the cistern!

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Wow... this may end up being a "Pinned" build if you finish as strong as you started! B)

Great job man! :salute:

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Looking really good!

Its great when we get to see the inside of things, and not just how they look on the outside. Very helpful.

Thx for sharing!

Saludos

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Oi - remind me never to stand next to you once you're sandy - I'll look like crap ;-)

great job :duim:

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Awesome job Terry! Great job reinforcing the inside of the trays for the mounting strip rivets. I do the same thing on my builds. Can't wait to see the finished product! :duim:

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Move along move along... No lol I mean looking freaking sweet Terry! Can't wait to see what you do with my cistern. :)

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Thanks everyone, glad you like the build so far!

Some great progress the past few days. It's mostly been spent on Gordonator's cistern, and the radio. I've created a knowledge sharing thread / how to on how I approached Gordon's cistern here. I hope this is helpful for those that have one.

How to mod / install Gordonator's cistern

Here's some updated images of the completed cistern. I'm pretty happy with the way it turned out!

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I also worked a bit on the radio. I know ultimately, I will be ordering one of the new Crashmann radios, but I thought I would build this one anyways as a backup / one to use in the meantime.

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I trimmed the radio edge and left a 3/4" thickness to the sides. I then cut 3/4" from the radio box sides before assembling it. I used the trimmings along with some "L" shaped profile styrene to assemble the box, to create an inner "lip". I know it's not necessary, I just found that it fits better - almost like a cookie tin.

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I'll probably use a hinge / rage earth magnets to close the radio box. I've also cut the hole for the dial. I have "something special" planned for the dial. :)

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Stay tuned for more updates on the stinger!

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Moving on to the stinger. I removed the foam, cut out the stinger dome cap, and painted the stinger Satin Slate blue. I also painted the top (or bottom) of the stinger black by masking it off with tape, and spraying top the satin black.

I found this plastic toilet connection pipe at a local home improvement store for a $1.50, so I thought I would try it out for the stinger tip.

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I drilled the hole in the faucet cover to the same diameter as the toilet pipe. Then forced the pipe through and hot glued it on both ends. It’s solid and not going to come off.

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I applied some hot glue to a section of toilet tubing about 2” from the top of the faucet cover, and also shot some glue around the inside rim of the stinger cap and slide it down the toilet tube. The hot glue will hold the stinger cap in place, and also helps stabilize the toilet pipe.

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I then cut the short section of black tubing that Crashmann includes in his backpack kits to 3.5” and test fit it over the toilet pipe, and whaddya know – it fits perfectly over the toilet pipe! I simply applied some E6000 glue to the toilet pipe before sliding the tubing on to hold it in place.

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I trimmed the toilet pipe flush with the Crashmann tubing, and I used a Dremel to cut that funky notch in the end of the stinger that I’ve seen in various reference pics.

I’ll paint this tip black, put the foam back in the faucet cover (remember to cut a round hole in the bottom of the foam to make room for the toilet pipe end that’s been hot glued in place)and the stinger is complete. I’ll use some simple aluminum brackets to hold the stinger in position under the lower seed trays.

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I like it Terry! Looking good. Can't wait to see what you do with the radio dial.

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Looking very good as all ways Terry.

i all ways check your topics, as i know you all way make top class work.

Once again, congrats whit your nice accurate pack coming up.

Keep up the good work bro ;)

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WOW!

This is amazing!

So much detailing... its awesome.

Great work bro.

Can't wait to see it finished.

Saludos

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I love the fact that you are using another toilet part for the backpack :D

I foresee this topic becoming sticky :duim:

Charlie

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Great job!!

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Some updates:

Attached frame cross bars via rivets

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Attached the stinger to the lower tray

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I added an L shaped aluminum bar inside the lower tray for more support for the stinger. It's very stable now.

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Attached the exhaust port via bolts

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Upper seed trays were attached seamlessly by way of L brackets mounted inside the upper tray, and zip ties running through the lower trays and around the frame cross bars. Works great!

How to: attach trays seamlessly

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Added some detail to the radio. I'll be getting the new Crashmann faceplate, but this one will have some details and holes drilled in the grill for now.

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Made some custom backpack straps. They are 2" webbing, with loop velcro underneath. I will make some pads that are modular and can velcro into place. I'll be adding a sternum strap with a quick release buckle

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*Note: I find that the stinger "sticks out" too much against my butt, because the cross bar at the bottom of the pack is too "low" for the Crashmann trays. This makes the pack stick out like crazy, and I'm not liking it.

I've decided to either extend the height of the cross bar, or take everything apart, and make a new frame with a higher cross bar to make more room for the stinger.

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Made taller frame, cut a notch out for Gordon's cistern

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Stinger sits much better now

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Painted the frame black, and installed the trays with the zip tie method in my tutorial

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Added the should straps

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Completed the shotgun shells, attached using rivets. Installed the mesh, backed with foam core.

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Moving onto the mortar tube, took a slightly different approach. I used Crashmann's clear "shipping tube" but filled it with expansion foam (for insulating door gaps) to make it stiffer / stronger. This has the benefits of the a light weight tube that is lighter than ABS or PVC, but still very rigid.

I used 2" ABS connectors installed inside the tube at mounting points. The bolt will pass through the frame, into the mortar tube, past the ABS connector, and into a nut hot glued into place.

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I also glued the bolt for the radar dish inside the tube and adjusted it for length to reach to the outer dish (Tupperware lid)

I made a simple "I" beam out of foam core / hot glue to make the tube more rigid.

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I extended the tube on the expansion foam applicator to reach into the mortar tube.

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Start spreading the foam slowly! It will make a mess, so have newspapers handy and do this outside (fumes). Only fill the tube about half way on each end and let it expand and spill out.

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Make sure to let the foam cure. I rushed it and put the caps on about 1/2 hour after the tube was full, but I found that even 2 days later, the foam at the ends was not completely cured since it's air tight inside the tube.

Don't worry about foam cured on the outside of the tube, you can easily cut it off with an exato blade and sand it smooth.

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After the foam is fully cured, I glued the caps on.

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Painted the tube black. I left one spot masked out for the TD control panel (I don't like to glue things on paint, it's a stronger bond if it's plastic on plastic)

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Mortar tube installed with dish attached. Everything is ROCK SOLID!!

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For the "Laboratory pipe", I just eyeballed the dimensions from the screen cap of the Stop that Ship! trooper inside the cantina when he crosses in front of Han.

I used some PVC pipe and some reducers.

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Sanded and ready to paint.

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Test fit

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I painted it, and fired some screws through the frame into the lab pipe. I also added some zip ties for strength / detail

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I've been adding more detail to the original Crashmann vac formed radio faceplate. I cut out a hole for the big knob and backed it with some scrap ABS, to make the opening recessed. Are those new knobs?!?

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Ding dong! Look what arrives in the mail today! :)

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That's all for now. All that's needed is to finish the radio, and a little weathering and the pack is complete!

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Love what you did with the old vac formed faceplate. (PM sent) Of course the new one is just awesome!

The pack really looks amazing Terry. Great job!! :duim:

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Looks freaking cool.

Two small things.

The bee stinger need to be shorter.

And the small box where there small tube comes up, whit the metal ring on, you need to add another small cut out tube over it, and then cut it /.

Keep up the good work bro.

Congrats whit the radio, can´t wait to get mine and add it on as well :)

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Thanks for the tips Rolf, I knew I could count on your sharp eye! :)

I'll make those changes, and continue to work on the radio.

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i like a lot your work Terry, very clean, nice and all add details.

it will be a amazing pack!!

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Thanks guys! Glad everyone likes the build so far.

Pretty much done the pack now. Fixed a couple things based on Rolf's feedback:

Fixed exhaust tube (added a tapered overlay section and zip tie)

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Shortened stinger (removed approx. 40% of the length to match Rolf's pack for reference)

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Finished the radio. I decided to finish my first radio, the Crashmann vac formed plate first before diving into the new one. This one will have an amp / speaker inside, playing the TD loop. I painted it black to match the other pack parts, added the new knobs from Crashmann, installed the switches, added mesh behind the speaker opening, added a plexiglass dial with print out behind it (I have something else planned for the other Crashmann radio) :)

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It's totally troopable now, I only plan to weather it a bit, and it should be good for deployment (let me know if anything won't pass and I'l fix it!)

Some shots of the finished pack

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