Well its been a bit, and I started this part of the build very hesitantly. I am not sure why I was not looking forward to the jetpack, possibly has to do with the amount of parts, or maybe it had something to do with the fact I am tired of bondo and sanding and filling and sanding some more. Whatever the reason I was purposely avoiding the very necessary jetpack.
So, I downloaded WOF jetpack template, bought a half sheet of Sintra and started tracing patterns.
Cutting 1/8" SIntra with an Xacto knife is a chore to say the least, the fore arm pump and blisters on the sides of my knuckles will attest to that.
Diving in head first I cut the majority of the large and major pieces. Armed with some PVC cement and a heat gun I set to shaping and gluing the parts together. Have I mentioned I do not like using PVC cement, not even a little bit. The main body went together rather quickly, even though I had to custom bend the main tube that runs down the centre.
Next I had to do some improvising. I could not find a tube that would fit the top section, I looked high and low and could not find a piece of PVC to fit properly, enter the bottle of Scotch, as I sat and had a drink I looked at the cardboard tube that the bottle of Scotch was held in and it just happened to be a perfect match. Cut, glue and voila! A tube that fits awesome, not only does it fit the space perfectly I was also able to use the lid as the base for the missile! Life is good.
So lots of cutting, heating, shaping, gluing, swearing and sanding, I was nearing the finish line of the main build. Next I have to fill cracks, holes, divets etc and sand it all down.
Here you can see my make shift missile clamp, the weights along with the dowel kept everything in line as well as assisted in clamping the glued and drying pieces.
The thrusters are made from 2.25" wood balls that I found at Michaels craft store and the top cone I made from a kids foam sun visor folded to the proper shape then filled with a mix of rondo. Once the rondo was hardened I peeled the foam off and like magic I had a solid topper the right shape and size.
Total weight of the pack is 3 lbs 14oz, which I feel is fairly reasonable.