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 Repulsor Pack for Orbital Drop V2

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Niabi


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Re: Repulsor Pack for Orbital Drop
« Reply #15 on: Sep 25, 2013, 03:54 PM »
Looks awesooooooome vod ;) I really really like it

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Re: Repulsor Pack for Orbital Drop
« Reply #16 on: Sep 25, 2013, 10:24 PM »
I really like that design you have there. Great job, this is the way things are supposed to be done carefully with precision.

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Karjair


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Re: Repulsor Pack for Orbital Drop
« Reply #17 on: Sep 26, 2013, 09:31 PM »
Looks awesooooooome vod ;) I really really like it

I really like that design you have there. Great job, this is the way things are supposed to be done carefully with precision.

Vor'e Vode! (hahaha mando rhymes). Seriously though, Thank you.

Solus Raam


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Re: Repulsor Pack for Orbital Drop
« Reply #18 on: Oct 21, 2013, 01:16 PM »
Whoa this is starting to look really cool. I'll be watching.

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Karjair


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Re: Repulsor Pack for Orbital Drop
« Reply #19 on: Jan 20, 2014, 04:02 PM »
So I have decided I'm not happy with where the pack is going. Mostly I have decided I hate large quantities of Bondo. Having discussed some options with Hondo Karr (Thanks for the advice vod), I will be making this pack out of sintra and only using putty to clean up the seams. Instead of the simple graph paper drawing I was working from previously, that led to some improvisations I was not happy with, I managed to model the pack in Sketchup well enough to use as a visual reference.  I also have a second copy of the same file saved with dimensions added in to assist in laying this all out to cut.  Overall I think I am happier with the new look of the pack than I was with the old.

Lessons learned from Pack V1:
1) When using drywall tape, don't tape it unless you are going to putty over relatively quickly. The tape adhesive is not very strong and will pull away from the piece, making it look like an unraveling mummy.
2) I need more practice working with Bondo before attempting to cover large areas.  The Bondo I have spreads like very thick cake frosting. I was unable to spread it out without causing ridges and swirls. The anticipation of having to sand this mess is what caused me to hold off on finishing the original version and look at my options.
3) This one is for anyone new who might be reading this... Our brother/sister Mando's are helpful. If you have a question, ask someone. Start a thread, send a PM, make a phone call. They're here to help you.

Since I don't want to necro my thread without at least some progress, here's a photo of the sketchup model I will be working from. Sometimes going back to square one is a good thing.


Carid Vhett


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Re: Repulsor Pack for Orbital Drop V2
« Reply #20 on: Jan 20, 2014, 06:50 PM »
Pity about the mess ups of V1. Best of luck with V2, design looks great.

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I understand, no prisoners, only trophies
Death is always smiling at you, it is only polite to smile back.
Mhi kisol, mhi briikase kisol, mhi tsad be vode.
Keep Moving Forwards - Monty Oum

Karjair


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Re: Repulsor Pack for Orbital Drop V2
« Reply #21 on: Jan 21, 2014, 10:48 PM »
     I spent the better part of yesterday evening laying out the main body of the pack. I had several bad starts as I was trying to figure out the best way to progress through the build. I remember very little from my mechanical drawing class back in junior high, but drawing through my intended points and not erasing the excess construction lines saved me.  As you see in the photo below I'm going to be folding the Sintra almost like a Pepakura except that the entire piece isn't connected. There is a piece on either side that will form part of the back (as it's worn) that connects to the main section via a 2" piece. I had some difficulty figuring out how best to lay out this piece until I noticed that I had left my construction lines in place on the main section. I used a compass to recreate a triangle that let me get a foothold and something to work from. I finished laying it all out and went over the lines to be cut or grooved with a sharpie. Solids = cut, dotted = groove.




     Today I purchased a V-groove cutter for foamboard and picture frame mats.  It wasn't exactly what I needed but it is sufficient. The blades don't cut a very deep groove in the sintra. I did some test bends and it still worked well enough to do the job.  When I returned home, the uncut armor pieces on the sintra were staring at me coldly so I cut them out. They're happy now and will be even happier when I make it to the armor party in February.  Back to the pack...
     A lot of cutting, and more cutting. Then carefully using the groove cutter where the folds would be. Broke out the heat gun and started heating the first fold, which didn't turn out as well as I had hoped. I overheated it a tad too much and it started to curl. Quickly turned off the heat gun and grabbed my cheap plastic speed square from Lowe's and used it to make my 90 degree fold.  The first couple folds are a little rough but serviceable. The folds for the more critical pieces that fold up and over were much better and I'm satisfied with how they turned out. Here are the results, I will have to fill those gaps and fair the curled pieces at some point.







The 4" PVC sewer pipe I cut from a piece lying around in my dad's hoard of scavenged materials that me might use 'someday'.  In the V1 pack I had intended this piece to be a tube as well but got impatient to build it and made it a box instead.  There isn't much to say about the last pic except that this is the current state of the build.  The pipe is being glued to the rest of the main body and will sit like this overnight while the glue cures.  The ruler laying across is to keep the pieces laying flat instead of pitching up. There is a bead of glue down the entire length of the bottom of the pipe and glue on the inboard corners of the pieces the ruler is laying across.



     So now I have some questions, Should I fill and fair the gaps and seams on this piece before building and adding the next one? The next piece will be the piece that runs up the center. Given my terrible Bondo skills, should I use something else to fill the gaps and fair the curled pieces smooth or just go with the Bondo?
Comments and advice always welcome, Thanks for looking.

Carid Vhett


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Re: Repulsor Pack for Orbital Drop V2
« Reply #22 on: Jan 22, 2014, 02:07 AM »
Go with bondo, but invest in an electrical palm sander. Or just sit down one day/night and start sanding. Put some music on and smooth it out.

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I understand, no prisoners, only trophies
Death is always smiling at you, it is only polite to smile back.
Mhi kisol, mhi briikase kisol, mhi tsad be vode.
Keep Moving Forwards - Monty Oum

Karjair


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Re: Repulsor Pack for Orbital Drop V2
« Reply #23 on: Jan 24, 2014, 05:09 PM »
Not much progress since the last update. I put some bondo on the inside of the seams and a few of the outside seams as well.  Ground down the bondo with the dremel tool and a grinding stone so that I could get into the corners, the mouse sander is just too big to fit. I cut out, folded, and glued the lower section.



I may pause the build here until after Ge'tal Veh's upcoming armor party.  I want to make sure I can get inside to install mounting hardware and rocket nozzles if I need to.  I am seriously considering making the central section either completely removable or having some other form of internal access for future upgrades. I'll be getting the bondo finished and sanded down on this in the next week or so before I install the central section or the repulsor pods on the sides.

Karjair


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Re: Repulsor Pack for Orbital Drop V2 (Now with 20% more progress)
« Reply #24 on: May 11, 2014, 02:30 AM »
So it's been almost 4 months since I last did any work on my pack.  Work has been keeping me busy. My kit might get done eventually, not holding my breath though.  :laugh: Some close friends Kuu and Jaelie from Murran clan started working on their kits, so I decided to get off my duff and get some work done on my own.

Ok... Had some issues with putting the repulsor units on.  I had originally intended to have the pods slide over the tube section, but I wasn't sure about the best way to lay out the ellipse to cut. It's an ellipse because the sides of the pods meet the tube at an angle. So I procrastinated (In addition to being busy at work). I layed out the main parts of the repulsor units, and cut them out.  Then I noticed that the shape didn't match what appeared on the 3D model I worked up. I checked my measurements again and found that I had made an error.  I managed to salvage it but for the faceted top of the units I will not be able to use those measurements from my model. I used the first cutout as a template and traced it onto the sintra and cut out the second piece. Heated, bent, no major issues (minor cracking in one bend that wasn't heated enough).  Dry fit the piece onto the pack... major gaps.  I had failed to account for the additional width that is created by bending the sintra. So... I broke the drywall tape back out, taped the inside of the seams with gaps and liberally applied hot glue. The tape kept the glue from gushing out.  Once the glue cooled down I began filling the gaps from the outside with the "Plastic Metal" Bondo in a tube.  This is where I am currently. Not all the seams have Bondo in them yet, I wanted to give it a chance to cure before I started handling it to finish adding the Bondo.







Comments and suggestions welcome. Thanks for looking.

Kuu


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Re: Repulsor Pack for Orbital Drop V2
« Reply #25 on: May 11, 2014, 03:00 AM »
Looks so awesome! I see Bondo in my future as well (Jaelie and her sister's kits). I too need more practice with sť Bondo.

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Karjair


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Re: Repulsor Pack for Orbital Drop V2
« Reply #26 on: May 11, 2014, 08:51 PM »
I made a little progress on the pack today. Most of the day was spent filling seams with bondo. I haven't started sanding yet.  I did get the main panels on the faceted top attached. I will wait to bondo them in until after I have the bevels attached.  Once again there isn't much left to actually do to complete the build. As I'm beginning to think about paint apps, I am wondering if anyone has any experience with painting over Plastidip. There are several small areas with divots that I would like to hide in as easy a manner as possible.  They don't really work as 'battle damage' for me but I'd rather not spend a lot of time sanding since the sander tends to scuff up the sintra pretty badly after a while.







Comments and advice welcome. Thanks for looking.

Carid Vhett


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Re: Repulsor Pack for Orbital Drop V2
« Reply #27 on: May 11, 2014, 09:12 PM »
Plasti dip, bondo, sand, primer paint. Sorry, it is the only way I can think of.

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I understand, no prisoners, only trophies
Death is always smiling at you, it is only polite to smile back.
Mhi kisol, mhi briikase kisol, mhi tsad be vode.
Keep Moving Forwards - Monty Oum

Karjair


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Re: Repulsor Pack for Orbital Drop V2
« Reply #28 on: May 11, 2014, 09:26 PM »
Plasti dip, bondo, sand, primer paint. Sorry, it is the only way I can think of.

Is this the order of operations or a list of methods? If it's the order, you bondo after the plastidip?

Carid Vhett


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Re: Repulsor Pack for Orbital Drop V2
« Reply #29 on: May 11, 2014, 09:29 PM »
Yeah, can be order. You can swap Plasti dip and bondo around I think. Plsti dip creates a seal, I have seen it used on EVA foam to paint it.

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I understand, no prisoners, only trophies
Death is always smiling at you, it is only polite to smile back.
Mhi kisol, mhi briikase kisol, mhi tsad be vode.
Keep Moving Forwards - Monty Oum
 


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