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 Post subject: Homemade ESB DarthVader belt boxes
PostPosted: Thu Feb 01, 2018 3:30 am 
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Joined: Fri Jun 02, 2017 11:05 pm
Posts: 14
Location: Queretaro, Mexico
Well, belt boxes are not cheap, and I can understand why, circuit making is delicate and time consuming. So I thought I could put together my own, but after looking for all the components, I only found them online all around the world, and shipping and taxes, it’s basically all the same as if I bought them for $200-300 usdlls
 
So I decided to make them as accurate as possible but at a 10th of the cost. This means I will have to put in 10x as much effort, but as a maker, 10x as fun.
 
My halloween boxes I made out of cardboard and resin, but they were quite rough looking , fragile and not accurate dimensions. So the new ones I’m making out of wood.

The wood are 3mm mdf/wood maquette boards for kids projects, $0.99 per foot sheet, and plain old PVA glue. I used the Hammond 1550C spec sheet and the template on the Sith forum for dimensions, though I did tapered them about 1mm more and enlarged them about 3mm because cutting & gluing tolerances. On +6’2” Vader Im sure 1/8” is imperceptible.

The green light borders and diffuser I made with wooden tongue depressors, again, from the kids projects supplies for $3 usd/pack and some aluminum tape.

Next step are the knobs which I will cut from $3 usd drawer hardware pull-bars and the pilot covers which I’m not sure if i will cast them on epoxy or vacuform them in PPL.

ImageImageImageImageImage
They’re almost done. I still have to bondo and sand the corners so they get that nice round filleted look of the hammond’s.
 
I also found out a real cheap easy way to get the buckle done with a couple of blind outlet covers. So I will show you once i get to it.
 
Cheers!


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 Post subject: Re: Homemade ESB DarthVader belt boxes
PostPosted: Fri Feb 02, 2018 2:56 pm 
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Joined: Fri Jun 02, 2017 11:05 pm
Posts: 14
Location: Queretaro, Mexico
Here they are with “bondoed” corners and a first coat of primer. So far, so good.ImageImageImage


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 Post subject: Re: Homemade ESB DarthVader belt boxes
PostPosted: Fri Feb 02, 2018 3:31 pm 
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Joined: Wed Apr 18, 2007 6:21 am
Posts: 612
Location: Colorado Springs, Colorado
Those are coming along great! Something to be said for making them yourself :thumbsup

Dave


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 Post subject: Re: Homemade ESB DarthVader belt boxes
PostPosted: Tue Feb 13, 2018 2:04 pm 
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Joined: Fri Jun 02, 2017 11:05 pm
Posts: 14
Location: Queretaro, Mexico
So, I tried to vacuform the button covers with no luck at all. I need a better heat source that is more evenly...
Image
So in the meantime, I’ll do the knobs, but not sure if I should go with the wide ones or the thinner ones. I probably go with the thinner ones since they are easier to assemble. Feedback? ImageImageImage


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 Post subject: Re: Homemade ESB DarthVader belt boxes
PostPosted: Sat Feb 17, 2018 2:08 am 
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Joined: Fri Jun 02, 2017 11:05 pm
Posts: 14
Location: Queretaro, Mexico
So Knobs time. So the knobs are commonly made out of an aluminum bar, but I could not find a supplier that sells just a few inches, and getting the whole 3 meter bar is not cost effective. So ended up using a pair of tire pressure gauges for $3 dlls, that had just the right diameter (9.5mm)and and sliced them up into 11mm long tubes.ImageImage
For the top I used 1” chicago screws, but because they are a lot thinner than the gauge tubes I had to find something to center the screw. I found a hard vinyl hose I had lying around and cut the centering sleeves and a back spacers.
I had to polish the top of the screw to erase the brand off. Then I assembled the tube with the sleeve and the screw and glued them with locktite to avoid any wobling.Image I widened the holes to fit the chicago screw through, then slipped on the vinyl sleeves, and that’s it!. ImageImageImage I think they turned out quite OK.


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