It begins!! Jetpack scratch build.

[Mando72]

So using the templates from the forum. I've began a jetpack build from scratch for my ROTJ Special Edition costume. This should be interesting.

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[VIARPE]

you do have courage
keep sending pics!

 

[Mando72]

Yeah this definately is not going to be a easy task. Going to need lots of bondo. LOL

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[Mando72]

Using 3mm sintra have the basic form, but the 3mm is tough to shape. And the bottom angle not exactly where i wanted it. But it will do.

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[Mando72]

Slowly but surely its beginning to look like a jetpack.

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[Mando72]

A little more bondo and a lot more sanding. But taking shape more and more. I almost got frustrated and walked away this morning, glad i didn't.

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[Mando72]

A little more bondo and a lot more sanding. But taking shape more and more. I almost got frustrated and walked away this morning, glad i didn't.

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[MoogMan]

It's really taking shape! I'll have to keep an eye on this thread

 

[Mando72]

Thanks for the encouragement! Decided to use foam to fill in between the tanks and outer panels to strengthen it from flexing. And to also fill in the area behind the rocket tube. Trim, shape then use less bondo to fill in the massive gaps near the tubes and smooth it.

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[Gregory]

That's what I did, around the tanks anyway.

 

[Mando72]

Yeah trimming the pieces. Going to give it a try around the rocket tube. If not i can always cut that out and start over. Crossed fingers LOL.

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[Mando72]

1st layer of bondo over trimmed foam. Only had to use a minimal amount of bondo. Now to add a smoothing layer and to blend everything then sand. Hoping to have this part of the jetpack finished today and primed then do any smoothing and pinhole filling using glazing putty.

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[Skyfire]

Even the weight of the PVC pipe adds up, for someone following in your footsteps, drilling large lightening holes in the pipes I the non exposed areas would save some weight, but not hurt strength.

 

[Mando72]

Nowhere near done yet, but now i can see alot of the places that need touch up and smoothing now. Have to build up the top edge for some reason these didnt line up and also left a gap so im going to have to build up a false ledge. This won't be the best jetpack out there, but will suit my needs just fine when finished. Stay tuned!

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[Mando72]

Even the weight of the PVC pipe adds up, for someone following in your footsteps, drilling large lightening holes in the pipes I the non exposed areas would save some weight, but not hurt strength.

Thats a great idea. Yeah most the weight is definately the pvc. Once complete I'll get a weight. As it sits right now with no rocket or thrusters its at exactly 5 pounds.

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[Mando72]

Well this is my stopping point for the week. Have to go back to work for the next four days, so I'll continue next days off. Whew!! I need a break anyway. Still have some smoothing of some rough spots to do.

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[WTFett]

Great progress!

 

[MMcFett]

What size pipe did you use? How did you get the templates to print out right?

 

[Mando72]

What size pipe did you use? How did you get the templates to print out right?

Used adobe pdf reader and printed them without any modification. 3 1/2 outer diameter upper tube. 2 3/8 outer on the tanks. 4 1/2 inner tube. Made the jetpack 15 inches wide from edge to edge on the sides of the tanks.

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[Mando72]

Did some painting of the jetpack body lastnight and began working on the rocket. Found a drain to attach to the bottom of the rocket to be able to make the rocket removable for transport but would hold it firmly in place during use. Had to grind some of the inside of the jetpack tube so it fit snug, but where it wasnt difficult to remove. Now building the actual rocket.

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