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  1. SPY007's Avatar
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    Dec 12, 2011, 7:45 PM - Fiberglass Jet Pack Build #1

    Just sharing a build option. I used the WOF plans and made several card board molds that I layered fiber glass/resin into. I used a release that allowed for most of the card board to easily peel off. I then assembled with fiberglass to build my jet pack. Plenty of Bondo needed. I detailed some of the parts builds in other threads. This is not an easy build, but here are some images. I made all the aluminum parts too. The stabilizer was made in part from a cheap Exato knife. The beacon was aluminum rod I shaped with with files as it turned in a drill press.

    Click image for larger version. 

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  2. SPY007's Avatar
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    Dec 12, 2011, 7:49 PM - Re: Fiberglass Jet Pack Build #2

    And a couple more images. This thing looked really sloppy in the early stages. I had to cut out the long rectangular shape on the back as it was a bit off on one end. It still needs more paint and weathering.Click image for larger version. 

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    Last edited by SPY007; Jan 8, 2013 at 11:12 PM.
  3. clonecollector's Avatar
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    Dec 13, 2011, 7:45 AM - Re: Fiberglass Jet Pack Build #3

    I like how this came out. I've never seen a build like this before. I bet its pretty light?

    I also like how your stabilizer came out! Show us some more shots of the beacon!
  4. Member Since
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    Dec 13, 2011, 11:43 PM - Re: Fiberglass Jet Pack Build #4

    Great work mate. It is amazing to see how well this turned out with that method.
  5. ObxFett's Avatar
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    Dec 14, 2011, 5:38 AM - Re: Fiberglass Jet Pack Build #5

    Nice Work!! I'm doing a similar project and just about to start glassing it...what type of release agent did you use? how much did this weigh when you finished?
  6. SPY007's Avatar
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    Dec 14, 2011, 10:33 PM - Re: Fiberglass Jet Pack Build #6

    ObxFett. The pack weighs about 6 lbs. I The "release agent" I used was actually Mink oil. Vasaline would likely work too. I have gotten some very dismissive comments from other replicators, but this technique is very inexpensive...and works. I have used it to restore a number of actual screen used props. If I have any trouble peeling off the card board- (I use 8.5X 11 backer board from Kinkos) - I just get the card board wet. It softens up and and can be scraped off. It is not always a perfect part, but Bondo grabs on to the fiberglass. The cardboard molds need to be re-inforced. Fiberglass can warp as it cures.
  7. clonecollector's Avatar
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    Dec 15, 2011, 7:59 AM - Re: Fiberglass Jet Pack Build #7

    Hey if works... that's all that matters! Its a great looking pack. Good luck with it!

    Quote SPY007 said: View Post
    ObxFett. The pack weighs about 6 lbs. I The "release agent" I used was actually Mink oil. Vasaline would likely work too. I have gotten some very dismissive comments from other replicators, but this technique is very inexpensive...and works. I have used it to restore a number of actual screen used props. If I have any trouble peeling off the card board- (I use 8.5X 11 backer board from Kinkos) - I just get the card board wet. It softens up and and can be scraped off. It is not always a perfect part, but Bondo grabs on to the fiberglass. The cardboard molds need to be re-inforced. Fiberglass can warp as it cures.
  8. SPY007's Avatar
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    Dec 27, 2011, 8:29 PM - Re: Fiberglass Jet Pack Build #8

    As requested. Based on the WOF template. The beacon was made by putting a 6 inch length of 5/8 inch aluminum rod in a drill press and using round and flat files to shape it while it turned. Once I got the basic shape, I switched to sand paper , then steel wool. After cutting to length, I center punched each end and drilled half way in from each end, so the bit wouldn’t go through crooked on either end. I used a dremel disc to start the little vents, then finished with a small drill like grinding bit. I drilled the bottom out a little larger and JB Welded in a hollow, threaded lamp fixture rod. Eventually I will cap it and add a light.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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    Last edited by SPY007; Dec 28, 2011 at 12:58 AM.
  9. clonecollector's Avatar
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    Dec 29, 2011, 9:50 AM - Re: Fiberglass Jet Pack Build #9

    Amazing job on the beacon!
  10. SPY007's Avatar
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    Jan 7, 2012, 4:30 PM - Re: Fiberglass Jet Pack Build #10

    Thanks. I will post pics if the finished pack, but I don't expect to work on again till spring.
  11. SPY007's Avatar
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    Jan 8, 2013, 1:47 PM - Re: Fiberglass Jet Pack Build #11

    Click image for larger version. 

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ID:	66449Still needs some weathering, but here are the latest pictures.

    - - - Updated - - -

    I just used a computer cable part for the dental screw.Click image for larger version. 

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  12. clonecollector's Avatar
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    Jan 8, 2013, 4:09 PM - Re: Fiberglass Jet Pack Build #12

    Great work!
  13. SPY007's Avatar
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    Jan 8, 2013, 11:19 PM - Re: Fiberglass Jet Pack Build #13

    Thank Clonecollector. I am painting my helmet right now. I used the same build technique.
  14. RafalFett's Avatar
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    Jan 9, 2013, 3:14 AM - Re: Fiberglass Jet Pack Build #14

    That jetpack looks excellent! Keep up the great work!
  15. hobbit057's Avatar
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    Jan 9, 2013, 5:09 AM - Re: Fiberglass Jet Pack Build #15

    Jeeper creepers that is amazing!!! Incredible build and paint up!! WOW!
  16. SPY007's Avatar
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    Mar 6, 2013, 8:57 PM - Re: Fiberglass Jet Pack Build #16

    Seated the adjustments plugs deeper. Here is my helmet and right gauntlet, both fiberglass. I used WOFs templates for both, but modified each a lot for more accuracy. I cut the helmet up and reworked it with Rafal Fett's templates.
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  17. Matty Matt's Avatar
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    Mar 6, 2013, 9:22 PM - Re: Fiberglass Jet Pack Build #17

    Fantastic work, absolutely fantastic. You should be very proud.
  18. SPY007's Avatar
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    Mar 6, 2013, 10:55 PM - Re: Fiberglass Jet Pack Build #18

    Thanks Matty Matt. I am very happy with it. Still a WIP, but I have a lot done. The helmet needs more weathering and dull coat. Too vibrant and and shiny.
  19. Member Since
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    Mar 13, 2013, 8:50 PM - Re: Fiberglass Jet Pack Build #19

    thats cool

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