Fiberglass Jet Pack Build

SPY007

Active Hunter
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
 
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
 
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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! :)
 
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?
 
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.
 
Hey if works... that's all that matters! Its a great looking pack. Good luck with it!

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.
 
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.

Beacon.jpg


Beacon2.jpg
 
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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

JetPackJan813.jpg


JetPackCUJan813.jpg
 
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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.

ThrusterDetail.jpg
 
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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.
 
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