Step 3: Sculpting the Parts
So we cut our parts out of insolation foam. This stuff is very dense and very pink. And perfect in terms of weight and ease of use. Jess and I had both used this stuff while at art school (SCAD) and with a little work you can get some great results.
But we also went one step further to really get things smooth and the corners sharp by coating each piece with spackle and then sanding it down. This really is the key to getting a foam pack look like machined parts. It even leaves a very nice and subtle texture that really feels like steel machined parts.
Then by adding a couple pieces of PVC you start to really get down the shapes needed for an authentic Proton Pack.
Again Home Depot was the store of choice.
(These are obviously just a couple of the parts we made, and don't include the battery pack etc.)