Nowadays, it’s easier than ever to get a pack started by buying a shell. There are a number of different materials to choose from.
Fibreglass is what the original packs were made from and is strong and durable material. Many pack shells have a number of the details moulded in saving you a lot of build work. As you can see from the pictures, fibreglass shells have plenty of room inside them for mounting your speakers and electronics. There are many reputable sellers of shells on www.gbfans.com.
www.benofkentprops.com/ offers fantastic shells, both hero and semi hero.
It is strongly advised NOT to buy from bobspropshop on ebay. His shells are thin to the point of cracking and the parts are of very poor quality. What you save in cost there you’ll spend in repairs.
Vacuum formed shells, such as those offered by www.studiocreations.com are a cheaper alternative, but aren’t as strong as fibreglass. You will also notice that the details, whilst there, are soft and rounded rather than being sharp and pronounced. Sometimes, due to the process in which these are made, there are small wrinkles in the plastic where it hasn’t completely adhered to the mould.
Scratch building can work out being your cheapest option. This is where you build the pack from the ground up. Recommended materials are MDF, styrene sheet and foamboard. All are easily shaped and have a great finish when painted up. Scratch building allows for some great use of
innovation, look at the above picture using a pringles can for a N Filter. It is advised NOT to use cardboard for a pack build. Visibly cardboard props will NOT meet clearance. Cardboard is also a very flimsy build material and will not last long in a convention environment, Ghostbusters get a lot of knocks and bumps in crowds, the last thing you want is anything coming loose ;)
If scratch building, it’s also highly advisable to bolt things together wherever you can. This will help keep the pack together and also make it easier to swap parts out should damage occur. This is also applicable to shell builds, bolt where you can! It makes for a much sturdier pack ;)