Lozzer86 Posted December 2, 2015 Share Posted December 2, 2015 Time for something a little different ! When I built my 'Move Along' Pack, it was built to last (probably indefinitely), but that made it really heavy to wear. Now that I've built it, I've come to realise that I could have made tremendous weight savings with a lot of the components.... So I've set myself the task of building a replica Pack 1 that's as light as I can possibly make it. This is the Pack we are aiming for.... It's seen a couple of times in ANH (Road Block, Falcon Take Off) and worn primarily by a Private with the black pauldron. I chose this pack because it's missing a couple of items (Exhaust Port, Bottle from the bottom of the Syphon etc.) which already reduces the weight. It's also got a really short mortar tube length. So this is my target... Make this Pack as light as humanly possible !!! This will be my build thread. I hope you enjoy it Quote Link to comment Share on other sites More sharing options...
Lozzer86 Posted December 2, 2015 Author Share Posted December 2, 2015 Right, on to business.... Let's go part by part and see if we can shave some serious weight down Number 1, The Radio... My new radio will basically be a block of high density foam, with CrashMann's faceplate. The hole in the middle is for a self powered, rechargeable MP3 Bluetooth speaker that i've stripped down, removed the weight from and rewired to trigger from an external switch. It starts to play as soon as the external switch is activated. Doing it this way, has cut down the need for external batteries and circuit boards. I removed the bulk of the weight from this MP3 speaker by removing the outer steel cover and top mesh. I replaced that with a small piece of lightweight pipe to amplify the sound. Here it is, inserted into the foam block... Once this foam block has the radio faceplate attached and a pleather wrap around, it'll be indistinguishable from any other radio. But it'll weigh considerably less. I can't do a weight comparison yet, as I need to troop in a TFA launch before I start disassembling my Move Along Pack. More to come Quote Link to comment Share on other sites More sharing options...
Strider Posted December 2, 2015 Share Posted December 2, 2015 Great approach, buddy. But I guess the only parts with potential weight savings are the radio and the tool box. I'm looking forward to seeing how you attach the radio face plate to the foam Quote Link to comment Share on other sites More sharing options...
Lozzer86 Posted December 2, 2015 Author Share Posted December 2, 2015 A gram here, a gram there Quote Link to comment Share on other sites More sharing options...
Felixdario Posted December 2, 2015 Share Posted December 2, 2015 great idea! Will follow this one! Will you build a light frame in accurate size? Maybe you could fill the toolbox with helium Quote Link to comment Share on other sites More sharing options...
Lozzer86 Posted December 3, 2015 Author Share Posted December 3, 2015 Ok, here's our benchmark ! My full size Pack #3 weighs an impressive ...... 6.23 KG or 13 lbs and 11.76 Oz. I'm not sure how that stacks up against other Pack 3's, but I do know how it feels after 3 hours on the shoulders I'm up for any suggestions folks, so if you have a great weight saving idea.... let's hear it ! Quote Link to comment Share on other sites More sharing options...
Strider Posted December 3, 2015 Share Posted December 3, 2015 Don't mean to be pessimistic but I'm lacking the fantasy to see where further weights can be chopped off besides the radio. Maybe the radar dish if you have one made from resin but that's probably ony a 150g difference. I find the aluminium frame pretty lightweight, not seeing any potential there. I think the old packs where about 4,5 kg but then again they were much smaller (I've posted a comparison pic somewhere). Yeah, I know, not being really helpful, lol. Quote Link to comment Share on other sites More sharing options...
Lozzer86 Posted December 3, 2015 Author Share Posted December 3, 2015 Have faith, brother ! The top tray of my current pack has some lengths of wood behind the front of it, so that I could screw in the Exhaust Port and Tool Box. All that can go I used steel fixings to hold everything together, this time we'll use Nylon nuts and bolts.... There's plenty of small savings that could add up to a big difference Quote Link to comment Share on other sites More sharing options...
nick.black Posted December 3, 2015 Share Posted December 3, 2015 Lee, I'll be very interested to see what you can achieve here buddy. This could have implications for all of us if you find some significant weight savings. Me, I'm a stickler for punishment and I actually think it makes part of the character that the kit is a bit heavy. It makes it a kind of trial to wear it and due to that I feel more bad *** than Tks. Sore shoulders are not fun though. Keep going buddy Nick Quote Link to comment Share on other sites More sharing options...
LoveMonkey Posted December 4, 2015 Share Posted December 4, 2015 Now that I'm approved it's time to start on my pack. As I start a part list I will follow this with much anticipation. Quote Link to comment Share on other sites More sharing options...
nick.black Posted December 4, 2015 Share Posted December 4, 2015 Lee, Weighed my pack and it comes in at 9.2 lbs (4.2kgs). This is a Karimoor frame with Boydy's trays. My radio made from PVC foam and bits of Perspex with resin dials weighs 550g. Hope this helps. Nick Quote Link to comment Share on other sites More sharing options...
Lozzer86 Posted December 4, 2015 Author Share Posted December 4, 2015 4.2kgs is quite a bit less than mine. I don't have a target weight, I'm going for the surprised approach Quote Link to comment Share on other sites More sharing options...
nick.black Posted December 5, 2015 Share Posted December 5, 2015 Haha yeh don't blame you. Any reduction in weight is going to be good though. Quote Link to comment Share on other sites More sharing options...
Lozzer86 Posted December 14, 2015 Author Share Posted December 14, 2015 *** UPDATES **** Here she is finished !!!! (Sorry, we did a massive fast forward as I only had 2 days to complete it between troops) This was actually harder than I thought. It's not the construction (removing weight but keeping it light), it's the sourcing of lightweight versions of the same components.... I must have spent 3 hours picking up bits of pipe and checking their weight against other similar pipes in my local hardware store. You also need to me mindful of OD and ID when ordering stuff. Not everyone makes it entirely clear what a 2 1/2" pipe is, and it can be widely out ! Things that cannot be changed or lightened; 1. The aluminium Karrimor frame 2. The Radio Faceplate (because I love the quality) Things that can be lightened; Everything else So everything else was lightened by removing material from unseen areas, using nylon bolts instead of metal, replacing existing items with lighter weight versions. As an example, my Mortar Tube was made from 'solvent weld' pipe and was held onto the frame with metal hardware. It is now held on with cable ties. The old pipe had a specific pressure rating for use in plumbing applications, so the walls were quite thick. By replacing this pipe with a similar outer diameter (OD) of a plastic postal tube, I saved a lot of weight. Same goes for the lab pipe ! You'd be surprised between all the different weights between waste pipes My foam radio saved a lot of weight too. I didn't weigh everything individually, but each component was was taken down to it's absolute bare minimum to keep it as light as possible. This went as far as using the minimum amount of pleather for the wrap around. I even cut the top off the antenna and glued it in place, as that's the only part you can see. No extra touches on the radio, no steel wire, no feet, no din socket etc. Again, it's grams we are looking at saving. I removed plastic from behind the air filter box and tool box on the seed tray areas, only used the shell of the air box (not the lid), even cut out the back of the tool box to save a gram here and there. The seed trays were fixed to the frame with nylon bolts and glued together with E6000. Again, all in the pursuit of weight saving I removed lots of material from the rear of the seed trays, but still keeping them strong... I told you it was going to be drastic !!!!!!! I won't go into why cutting circles retains the strength, but it does if done correctly. This was an old trick from my racing days Again, it's only grams saved, but all the grams add up. Then I covered the holes with adhesive felt. I also upgraded my Radar Dish to a more accurate smaller sized one and added the much sought after toilet syphon. The radar dish backing pad and radome were made of nylon instead of rubber to save even more weight. Even the toilet syphon had a shave before it was bolted to the seed tray (again, with Nylon bolts). And the end result of this extreme diet ??????? 3.84 Kilograms !!!!! (8.58lb) including all parts, straps and ammo pouch Heres a comparison from my old vs new pack weight. So against my old pack, I saved almost 2 and a half kilos and it's still just as strong Quote Link to comment Share on other sites More sharing options...
nick.black Posted December 14, 2015 Share Posted December 14, 2015 Awesome, awesome work Lee, really well done with this. Look forward to seeing it. Nick Quote Link to comment Share on other sites More sharing options...
LoveMonkey Posted December 15, 2015 Share Posted December 15, 2015 This is a great guide, awesome job! Quote Link to comment Share on other sites More sharing options...
Strider Posted December 15, 2015 Share Posted December 15, 2015 Wow, great job, Lee! Quote Link to comment Share on other sites More sharing options...
Lozzer86 Posted December 15, 2015 Author Share Posted December 15, 2015 Thanks guys Trooping tomorrow, so will report back on the difference. Hopefully it will make it easier on the longer troops ! Quote Link to comment Share on other sites More sharing options...
Strider Posted December 15, 2015 Share Posted December 15, 2015 It's not only the weight though, how the strapping fits and return edges of the armor can also have an impact. Have some issues in this regard with my new backpack as well ;-) Quote Link to comment Share on other sites More sharing options...
Lozzer86 Posted December 15, 2015 Author Share Posted December 15, 2015 Here's a random selection of build pictures from my phone if it helps anyone Quote Link to comment Share on other sites More sharing options...
Lozzer86 Posted December 15, 2015 Author Share Posted December 15, 2015 I'm looking forward to seeing how you attach the radio face plate to the foam Small Neodymium Magnets 1 in each corner, countersunk and hot glued into the foam, then corresponding ones glued onto the faceplate with CA. It's got plenty of hold (not forgetting that my pack has a strap that goes all the way round the front too). Quote Link to comment Share on other sites More sharing options...
Strider Posted December 15, 2015 Share Posted December 15, 2015 Nice solution and the strap should definitively do the trick if all else fails ;-) Btw, your cistern looks great - is that a mod from Gordo's? Quote Link to comment Share on other sites More sharing options...
Lozzer86 Posted December 15, 2015 Author Share Posted December 15, 2015 Thanks buddy. The Syphon was a real find. It's 'new vintage stock' from a specialist company in the UK. They had me on the list for months and finally one came up. Been saving it for this pack Quote Link to comment Share on other sites More sharing options...
Strider Posted December 15, 2015 Share Posted December 15, 2015 Haha, I didn't know the vintage trend goes so far as to include old syphons ;-) Certainly a win for the sandtrooper community! Quote Link to comment Share on other sites More sharing options...
LoveMonkey Posted March 29, 2016 Share Posted March 29, 2016 Love this build, so amazingly done! I have a question and hopefully this doesn't sound dumb, but I'm having a hard time visualizing the answer. You said that you used nylon screws to attach the foam to the seed trays. Does this hold up well? I am really interested in using the foam for the radio and tool boxes but I can't figure out a good way to properly mount the foam to the seed trays. Any insight would be awesome. Quote Link to comment Share on other sites More sharing options...
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