This was originally posted on my old blog. It is a very popular page, so I wanted to make sure I included it on my new site. The wording might be weird since I just copied, pasted and added a photo gallery.  Especially with Halloween this week. You still have time to build one, so here we go!

So your kid wants a Proton Pack. Where are you going to get one? Who are you going to call? Well, I've put together a short tutorial on how to slap one together with some house hold items. I had most of them laying around my basement or kitchen to start out and I think I did a pretty good job. It's pretty durable (if you use enough hot glue) and the kids will have a field day. I'm mainly doing this, because no one on the web has a quick and easy pack to build for kids. So, here it goes. Just skip the wood and use more cardboard if you're not powertool savvy.

WARNING: FOLLOW THESE INSTRUCTIONS AT YOUR OWN RISK. ALWAYS USE PROTECTION WHEN WORKING WITH TOOLS.

Click here to check out the first half of this tutorial "How to build a proton pack for kids!"


I apologize for taking so long to put up the second part to this tutorial. I didn't think I would get so many emails and comments on the subject. I will make a PDF later with more precise instructions and some measurments, but until then this should get you started.

• You will need:
• About a foot of 1x4 pine board
• .125" Masonite (hard board)
• 12" of PVC pipe (1" outside diameter)
• Bicycle handle
• 1" wood screws (a handful)
• Hot Glue
• Wood Glue
• Wire harness organizing stuff. (.5")
• 5/16" wooden dowel
• .75" OD clear rubber tubing 1.5" long
  

STEP 1Start by cutting out an angled wedge system (see picture on right) and attach to proton pack arm with hot glue. I made mine by cutting a pine board, 1.5" wide, on a table saw with a 45 degree angle. I then sliced it 1.5" leng-wise which gave me two identical pieces which I angled across from each other (as seen in picture)

STEP 2 Now you can build your WAND BODY. The wand body that I made is aproximately 4"x3"x3". Cut out two pieces of pine to the dimensions of 4"x3". Measure in one inch from an end and lop off a 45 degree angle. I will attach a diagram later. After those pieces are cut, sandwich the PVC pipe in between them and measure the total width. This measurment will tell you how wide your Masonite needs to be to cover the front, back, top and bottom of wand body.

STEP 3 Take the measurement acquired from STEP 2 and rip a piece of masonite to that width. Or cut with a jig saw or hand saw. Move the PVC pipe to the side. Now measure the top, bottom, front and back lengths and cover them with the masonite. Hot glue everything together. At the very end, drill piolet holes and put in wood screws to keep everything extra sturdy.

STEP 4 Drill holes to match the outside diameter of your PVC in the front and back of the wand body. (I had to use a 3/8 drill bit and enlarge the hole with a dremel because I did not have forsner bits at the time. I suggest a nice forsner bit)

STEP 5 Slide PVC through the back hole and out the front. I left about 3.5" out the back for the bicycle grip. Once the PVC is in place, use 3" wood screws (pre drill first) to ancor the PVC through the body.

STEP 6 This step was a lot of trial and error. I measured the top and bottom of my Wand Holding Wedge and created a shape to slip inside. I kept working a piece of masonite until is slid in nicely. Round the cornders and sand everything smooth so the wand doesn't get stuck in the groove. After I finished that, I mounted the piece to a .75"x1.5" pine board and screwed the whole thing to the side of the PROTON WAND using 3" wood screws.

STEP 7 Now that the Wand is complete, take this time to paint the entire thing black with the paint from the first part of this tutorial. When the paint is dry you can then slip on the bicycle grip. I used some hand sanitizer to lube the PVC. Make it easier to slide on and it evaporates.

STEP 8 Take your .5" cord organizer tubing (found at Staples or other office suppliers) and put about two inches of wooden dowel inside of one end. Now put it inside of the PVC tubing where the handle is. Fill in all around it with hot glue. Now drill a hole where you want the WAND WIRE to attach to the proton pack (make sure it is part of the wooden subframe). Drill a hole and insert a dowel with some wood glue on it. Then cover the dowel with hot glue and slide the cord organizer over it. Use the tie wraps it came with to tighten it around the dowel while it sets.

STEP 9 A nice finishing touch is to add a piece of .75" clear hose to the hole in the tip of the wand. I just used rubber hose because I had it laying around. Everything I used was already laying around my house. A sort of recycling project. I also used some silver paint to dry brush areas so it seemed like the paint was chipping off of metal rather than wood.

Please send me some pictures of packs that you make for your kids. I'd love to post some up on the website. You can also comment suggestions on my blog to help other people. I'm sure they will appreciate it.