Fiberglass Jet Pack Build

  1. #1
    SPY007's Avatar
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    Fiberglass Jet Pack Build

    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.

    bottomcaps-jpgcapmolds-jpgcardboardmold-jpgdetails-jpgnearcompletion-jpgparts-jpgpulls-jpgring-jpga

  2. #2
    SPY007's Avatar
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    Re: Fiberglass Jet Pack Build

    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.glassingcaps-jpgmold2-jpgbodyglassed-jpgfittingbottomcaps-jpg
    Last edited by SPY007; Jan 8, 2013 at 10:12 PM.

  3. #3
    clonecollector's Avatar
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    Re: Fiberglass Jet Pack Build

    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. #4

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    Re: Fiberglass Jet Pack Build

    Great work mate. It is amazing to see how well this turned out with that method.

  5. #5
    ObxFett's Avatar
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    Re: Fiberglass Jet Pack Build

    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. #6
    SPY007's Avatar
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    Re: Fiberglass Jet Pack Build

    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. #7
    clonecollector's Avatar
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    Re: Fiberglass Jet Pack Build

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

    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. #8
    SPY007's Avatar
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    Re: Fiberglass Jet Pack Build

    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 beacon-jpg   beacon2-jpg  
    Last edited by SPY007; Dec 27, 2011 at 11:58 PM.

  9. #9
    clonecollector's Avatar
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    Re: Fiberglass Jet Pack Build

    Amazing job on the beacon!

  10. #10
    SPY007's Avatar
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    Re: Fiberglass Jet Pack Build

    Thanks. I will post pics if the finished pack, but I don't expect to work on again till spring.

  11. #11
    SPY007's Avatar
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    Re: Fiberglass Jet Pack Build

    jetpackjan813-jpgStill needs some weathering, but here are the latest pictures.

    - - - Updated - - -

    I just used a computer cable part for the dental screw.jetpackcujan813-jpg

  12. #12
    clonecollector's Avatar
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    Re: Fiberglass Jet Pack Build

    Great work!

  13. #13
    SPY007's Avatar
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    Re: Fiberglass Jet Pack Build

    Thank Clonecollector. I am painting my helmet right now. I used the same build technique.

  14. #14
    RafalFett's Avatar
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    Re: Fiberglass Jet Pack Build

    That jetpack looks excellent! Keep up the great work!

  15. #15
    hobbit057's Avatar
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    Re: Fiberglass Jet Pack Build

    Jeeper creepers that is amazing!!! Incredible build and paint up!! WOW!

  16. #16
    SPY007's Avatar
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    Re: Fiberglass Jet Pack Build

    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.
    Attached Thumbnails Attached Thumbnails fettparts-jpg   thrusterdetail-jpg  

  17. #17
    Matty Matt's Avatar
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    Re: Fiberglass Jet Pack Build

    Fantastic work, absolutely fantastic. You should be very proud.

  18. #18
    SPY007's Avatar
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    Re: Fiberglass Jet Pack Build

    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. #19

    Member Since
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    Re: Fiberglass Jet Pack Build

    thats cool

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