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3D Printing A Ghostbusters Proton Pack – Part 3

I’ve got most of the 3D printed pieces put together now.

To keep them all together, I’ve glued them and then melted the edges together. For some of the parts that won’t be see on the outside, I’ve melted holes through the sides to join them a little better. The goal here is to minimize movement between pieces.

I’ve started to attach the brass fittings and hoses while paying careful attention to the color and how the hoses are positioned. Some of the close ups of the real, screen used packs from GB1 and GB2 have revealed differences in the hoses and brass fittings. So I made sure that I ordered the correct fittings for a GB1 pack.

I had ordered a package of hoses that were supposed to match the hoses on the proton pack from GB1, but noticed that the yellow hose was way too bright and not the right brand. So I found one on Ebay that is the right brand and shade.

To attach the hoses, I felt like simply gluing them into place with hot glue wasn’t going to hold very place very well if something got snagged on them (and I’m sure they will). So I used a screw inserted into the hose and screwed as tight as I could get it without breaking the hose. Then the end of the hose with the screw fits inside the fittings nicely. With some hot glue, it holds really well.













Using my soldering iron, I was able to melt the holes that we in the 3D prints so that I could screw the brass fittings into the part really easily. As it the melted part cools, I can slowly start turning the brass fitting so that it forms a screw hole for the fitting itself. For the most part, I just hand tightened these and they feel like they’ll be secure enough to the pack where they won’t budge. I may dab some glue on them just to make sure.

The Proton Pack Wand

There are few Sci-fi movie pieces of equipment that are as recognizable as the Proton Pack. The key part of the pack, the wand, has many intricate parts, knobs, dials, tubes, etc. I started printing and buying aluminum machined parts for the wand probably before I even started building the pack. Eventually I realized I had the bulk of the parts and started laying them out to assemble the wand.

Proton Pack Wand parts

Proton Pack Wand parts

The first thing I did was start planning the placement of all of the knobs and dials. And there are A LOT. The wand was way more complex than I was expecting and just figuring out which knob goes where made me look at reference images for quite a long time.


Sided knobs

Front knobs and Clippard

Front knobs and Clippard

Front knobs and Clippard

Back panel knob










Next I screwed the handle on the main grip of the wand after painting the grips black. They were originally a brown resin that I had specially made since the originals were brown resin with a black finish. I haven’t decided if I’m going to “age” the pack yet or not. The way that I’ve painted all of the parts, if there is a scratch or a chip in the paint, it should look natural and like normal wear and tear similar to the screen used packs.

Wand Handle Grip

Wand Handle Grip

Inside gun box attaching handle tube

Inside gun box attaching handle tube










Next I needed to assemble the wand tip, clear tube, and secondary grip. But there were a few things that I noticed after looking at the screen used wand. First, there is a wire running under the grip the entire length of the tube. Next, there is a bit of electrical tape here and there. I decided to loosely fit these items together because I’d likely need to take them apart when I install my electronics and when I finish my wand pop mechanism which I’ll discuss next.

Clear tube assembly

Clear tube assembly


Wand Pop Mechanism

If you’re going to build a Proton Pack Wand, there is a big question you have to answer first: are you going to have a wand pop mechanism. First, let me explain what the wand pop mechanism is. There are really only two scenes in the movie where they show the clear tube extending, The first is where Ray steps out of the elevator at the hotel on their first real call. The second is in the scene before they fire their wands at Gozer.

Here is a video of someone demoing the wand pop mechanism on a machined wand prototype.

As you can see, there isn’t much to it. The wand extends a few inches after pulling a green tube-covered brass lever. It’s not much, but if you want your pack to be screen accurate, this has to be done. The problem is that there are only really a hand full of people making these kits, and it takes a bit of work to get them setup in your wand. I guess the bigger problem is that not all wands are the same. Some are 3D printed and some are machined aluminum. Some are even resin or molded from other things.

So, because I love a good challenge, I decided to start modeling and designing my own pop-mech for my wand. And as with everything on this pack, it’s much more difficult than I expected. I’ve spent probably 50 hours modeling, printing, fitting, adjusting, and breaking parts for this but nothing solid yet. I’m close, but just not there yet. Part of the reason I’m taking my time with this is because I’m waiting on the electronics for my pack (which should be here in a few weeks!). After I get the electronics, I’ll have a better idea of how much room I have in the gunbox area and how long the wires are that I’m dealing with.

Here is an image of basically what I modeled my wand-pop mech on:




The difference here is that my gunbox opens differently than this one, so the parts need to be engineered slightly different. It’s the basic idea at least.

There are a few concerns that I have with the wand-pop mech that I’ve designed. First, there is a massive BANG! inside the gunbox when you release the trigger. I’ve broken a few parts just testing things. If my gunbox broke, that would really set me back some time on finishing this pack. So I have to design this so parts don’t break and if something does, it’s not my gun box. The other concern is that the wand-pop mechanism may not be very easy to assemble for others or retro-fit to wand gunboxes that aren’t setup like mine.

Here is the Thingiverse page for my wand-pop mechanism:

Wand Pop Mechanism

Wand Pop Mechanism Prototype


I finally got around to putting on the stickers I got a while back. Some of them I’m going to hold off on putting on. I need to apply some kind of clear coat on them to keep them from coming off. They are chrome stickers on very thin metal of some kind and look great. I got the ones that are “worn” looking.


Stickers look good

Here is a side by side of a screen used pack and mine. The dimensions and layout are very close. It’s looking really good.

Side by side with screen used pack. My pack is on the right.

Side by side with screen used pack. My pack is on the right.

3D Printing A Ghostbusters Proton Pack – Part 2


Some time has passed since my last post. In that time, the entire country has locked down because of the Coronavirus. I’ve switched from working on this to 3D printing masks for people to wear. I’ve not made many of them, but the ones I did make turned out really nice.

Fortunately, I’ve been able to work from home for my normal web development job. Many others have not been able to work at all. My wife and I have tried very hard to support local businesses and shops to keep their employees employed and, hopefully, keep them in business through this trying time.

On the flip side of this, I’ve had a little extra time here and there to tinker with the parts for the proton pack and assemble them. As it stands right now, I have all of the parts 3D printed for the entire main body of the pack. The wand is a different story which I’ll cover in a bit.

proton pack parts

3D printed Proton Pack Parts

I’ve started sanding and priming all of the parts to try to remove the print lines out of them. Some parts were easier to sand than other because of angles and curves. I started with an 80 grit and then went up to an 400 grit. Some parts that will definitely be visible or examined up close I sanded with 1000 grit. Afterwards everything was coated a minimum of two times with grey automotive primer and sanded again.

Automotive Primer

Automotive Primer

To join parts together I used several methods. The easier way of joining parts is to super glue them. I used Gorilla brand super glue gel and found out very quickly that you have to have the parts perfectly aligned the first time because they join quickly.

A second method I used to join parts, mostly on the back of the back and in places less visible, was to melt them together using a soldiering iron. I found this to be a very strong join with little effort, but beware…’ll completely ruin your soldering iron tip. A soldiering iron is also really useful for melting PLA to make screw holes or enlarging holes for nuts and bolts.

For some of the parts that needed to be put together, and then sanded with filler added, I used a combination of both of these methods. An example here of this is the bumper arm that goes around the cyclotron. This printed in two large parts that needed to be assembled. I started out with glueing them together very carefully so that they were perfectly aligned. Next, i used a soldiering iron to melt them together

Cyclotron Bumper Arm

Melting together Cyclotron Bumper Arm

Cyclotron Bumper Arm

Super Gluing the Cyclotron Bumper Arm








For most of the main parts of the pack, I drilled small holes through the parts and secured them together both with glue, a bolt and nut, and melted them together. The pieces feel solid now and don’t give or pull away from each other. Here are some examples of bolting them together:












After sanding some of the melted areas and making sure any of the excess PLA is removed from parts, I took them out to coat them with layers and layers of primer. Then sanded them again. Then primed them again.

Primed Proton Pack Parts

Primed Proton Pack Parts

After priming, sanding, filling, priming, painting, sanding….it was finally time to paint some of the parts. Using a tip from a fellow Proton Pack builder I met online, I decided to try out Truck Bed Liner Spray. The particular person that mentioned that to me said they loved the texture it left, and I have to 100% agree. It feels industrial and rustic.

Truck Bed Coating

Truck Bed Coating

I’ve started making “fake” weld lines as well on some parts. I kind of wish I had a larger “bead” glue gun, but the one I have will have to do. You’ll be better off getting a glue gun with a low heat switch on it so the glue actually doesn’t melt or warp parts. Once you get a weld line the way you like it, don’t prime over it. Just put a quick coat of paint over it, otherwise the weld line looks a little dull. Or at least that’s what I thought.

Weld line on the booster

Weld line on the booster

So far things are looking good!

Getting it assembled

Getting it assembled


I’ve got most of the parts now including the ribbon cable, Clippard, hoses, and all of the brass fittings.









I’ll post part 3 in a few days hopefully.

Here’s part 1.

3D Printing A Ghostbusters Proton Pack – Part 1


My home office has become a bit of a shrine to movies, music, and general things that I love.

I’ve got props from Star Wars that I’ve made or bought. Lightsabers, figures, and small X-wings and Tie fighters. A large model of the Millennium Falcon and a Darth Vader Helmet.

I’ve got a real metal reproduction of the catspaw dagger that killed the Night King from Game of Thrones along with some really nice custom artwork that I had printed for the display.

I have parts of the screen used Delorean from back to the Future (part of a Kickstarter I helped fund to restore the car). I have replica props from the Indiana Jones films. An arcade machine that I built a few years ago. I’ve got a Disney monorail system that goes around the ceiling of my office as well.

There are a few things missing from my office that I think about a lot and have always wanted to make.

Since I was a kid, I have always wanted a “real” proton pack. I used to walk around with this suitcase that I had with backpack straps on it and put a garden hose out of the side of it….pretending that I was Spangler or Venkman battling Zuul and Gozer.

As far as movie props go, the Proton Pack is one of the most iconic pieces of equipment in all sci-fi movies.

Research & 3D Print Files

To start out, I began reading everything I could on other pack builds and ways of constructing them. And there are A LOT of blog post and forums about the subject, with GBFans being one of the best resources. I’ve seen proton pack builds where people carved everything out of insulation foam. I’ve seen wood builds that must weigh a ton!

Then there are people that take the easy way out and just buy pre-fabricated shells and dress them up. To be honest, I don’t blame them at all for doing that because what I’ve realized is this is a time consuming project for almost everything. I’ve read several blog post that concluded “this took way more time that I was expecting”. So give yourself a lot of time. Don’t rush it either because you’re gonna want this to look awesome and be something you can display in your home.

Something else that you’ll find a lot of is that people are buying these “Spirit” brand Proton Packs and simply upgrading them with parts. The issue here is that the Spirit packs are only 80% in size and don’t have all of the real things like the ribbon cable or full sounds and things. But I want as real as possible so I’m not interested in them at all.

Since I want to 3D print my proton pack, I started looking through all of the different proton pack designs and files that are on One thing that I noticed, but not after I had already printed some parts, was that there are a lot of proton pack designs that have been reduced by 10% or so for kids or for smaller framed people. They aren’t full size designs, so stay away from them!

I ended up settling on a design by DancinFool82:

He does all kinds of cosplay designs and prints, some of which are incredible. Overall, he had the most parts that I could print on my smaller 3D printer and I liked some of the details in his design. But before I start printing parts, I decided to contact him via his Facebook page and make sure it was a full size design. He quickly wrote me back and confirmed that it is a 100% full size proton pack design. So here we go, I found my design!

Proton Pack Parts

The proton pack is actually very intricate and composed of lots of different parts. It was designed to look cobbled together and homemade, or at least made by someone that knew what they were doing. I started learning the “lingo”, if you will, and thought about how I wanted to approach my build.


It wasn’t long before I realized in all of my research that the proton pack from the first Ghostbusters Film and the second one are different. The image posted above is actually a GBII (Ghostbusters 2) Proton Pack. You can tell this pretty easily by looking at the ribbon cable and the crank generator.

The ribbon cable on the original GBI Proton Pack is made up of some rainbow colored cables, some grey cables, and appears to be custom made as no one has been able to locate an original one. The GBII Proton Packs have an all rainbow colored ribbon cable.

GBI Ribbon Cable on top. GBII Ribbon Cable on bototm.

GBI Ribbon Cable on top. GBII Ribbon Cable on bottom.

After looking at Ribbon Cable suppliers and comparing the cost of the two, it was surprising that almost no one supplies ribbon cables that look like the first GBI Proton Pack. I only found one source and they are selling them for $50+ and the cable is only 30 inches long. Right now, I can’t justify spending that kind of money on it. So for now, I’m going with the GBII style Ribbon cable called a Spectra model #132-2801-060. Here is a page all about these ribbon cables:

The Crank Generator Knob on the GBI Proton Packs are grey, while the GBII Generator Knobs are grey. Here is a good page about the knob: There are actually a lot of people selling resin cast knobs for way to much just to cater to the GB Fans that are building their Proton Packs. But, you can find several distributors selling the real deal part online and on Ebay. I would caution you to look for parts that aren’t marketed towards Proton Packs or GBFans and you can probably find them for cheaper.

Aside from those differences, most visible differences aren’t apparent and most people won’t notice.

What I’m planning on building is a hybrid Proton Pack with a GBI crank and a GBII Ribbon Cable. Eventually I’ll try to upgrade my ribbon cable to make a GBI pack but, as I said before, I can’t justify the $50 that is being charged for it. I’ll probably feel differently once I get the pack done.

HUGE Parts

In terms of 3D printer beds, the Proton Pack files are huge. I know a lot of people that print and have all kinds of sizes of printers, but not as big as some of these parts. There are particular parts of this build that I’ve seen sliced up different ways; mainly the Cyclotron (round part at the base of the pack), so they can be printed on smaller printer beds.

Since I have a smaller printer (Monoprice Mini) and these parts are already huge, I decided it was worth my time and money to send off these prints to be printed completely in one piece instead of printing them individually and in pieces, then gluing them together. I went with the website TreatStock to find a printer since they have reviews and a lot to choose from. When you load in the prints, it will try to find fabricators that have printers large enough for your parts. Some of these parts are so large that there were only a handful of people that could print them in the country.



I found that these parts were more sturdy, smoother, and generally better quality than I could produce if they were glued together. I had them print the entire Cyclotron, the Crank Generator Case, the arms for the bumper, the wand grips, the wand “gunbox”, the ion arm, the boosters and the power cell box. This might seem like a lot of parts to have printed for me, but I assure you, there are MANY more parts that I’m printing myself.

The Motherboard

As with a computer, the motherboard of the Proton Pack is what everything connects to that makes it run. There are blog post where I’ve seen people make these motherboards out of old aluminum signs, wood, particle board, plywood, MDF board, and even cardboard.

I’m on the fence with this one and stuck between cutting this out of sheet aluminum, or MDF board. I feel like aluminum would be more realistic (the originals used it) but also harder to work with. I already have MDF board from my arcade machine build, but it would also be heavier.

The first thing I needed was a template though. This was harder to find than I thought it would be.

I found this PDF of a template for the motherboard posted by Bextia on GBFans. I’ve printed it out and the upper left corner of the template seems misaligned or not correct. That particular page didn’t fit the rest of the template once I cut it all out.

So after reading a lot of blog post on this subject, I’ve made the decision to get all of the parts printed, fasten them together, trace them, and then cut my motherboard. Almost everyone that makes the motherboard first or orders one has issues with their parts not fitting right or being misaligned.

I’ll stop here for part 1.

Here’s part two.