SPIRIT PACK CYCLOTRON MOD

TOOLS:

• Drill

• Dremel/Rotary tool

• Cut off wheel attachment

• Sanding drums

• Sanding paper and blocks

• Body filler (I use UPol smooth body filler)

• Glue/Epoxy resin

• Primer and paint

Step 1

First remove all components on the pack that can be disassembled to remove the chance of damage and to have a clear work area.

(Remember where everything goes, take pictures too they will help with reassembly.)

(The pack should look like pictures labelled ex 1 + ex 2)

Step 2

Next, whilst using a Dremel/Rotary tool with a cut off wheel equipped remove the existing

cyclotron using the stepped ring as reference. Try to keep a small part of the vertical wall intact to use as an alignment when you slide the new one over. You will also want to cut through the moulded on bumper to get rid of the majority of the material.

(Note: The more material you remove the more structure is being removed and it will become flexible.)

Step 3

After the main chunk is removed, you will then want to cut out around where the moulded bumper meets the cyclotron as well as the base of the existing N-Filter.

(Note: Cut as close as you can to the surface and then use sanding drums or sanding paper to level it out.

Be careful as the soft plastic will be eaten fast by sanding.)

(See ex 3)

Step 4

The next step is to carefully use the cut off wheel to trim off the bumper details on the side of the main body.

Again use the wheel to remove the bulk of the material then use sanding drums and paper to make it smooth.

(see ex 4)

Step 5

Now that the removal is complete you can begin rebuilding.

The first thing to do is to place the new cyclotron over what is left of the old one using the small lip to centre it.

When you're happy that it fits well glue it in place making sure that the 4 circle holes are properly aligned.

(I use 2 part epoxy resin as a glue as it is extremely strong and will glue anything together.)

(Remember to key up the surfaces first before applying the glue.)

Step 6

When the glue has dried you can test fit the new N-Filter. Remove any material necessary to make it fit right then like before glue it in place on the inside of the pack.

I found it helpful to tape the N-Filter in place whilst I do this as the hole from the old one makes it tricky.

Step 6

Next you will need to find some material to block up all of the holes left by the bumper and N-Filter. I used plastic offcuts but bits of card should work as well. Glue them in place inside of the shell, this will provide a surface for you to use the filler on to smoothen over all the holes making it look like one piece.

Step 7

When all the blanks have glued in place and solid the next step is to mix up some body filler. Smearing it over each spot where there is a hole along with the seam between the N-Filter and cyclotron as well as the gap between where the new cyclotron meets the stepped ring on the existing pack.

(Note: Don't worry about smoothing it out until after is has dried, it is far easier to put too much on and sand it back then worry about making it look nice at this point)

Step 8

Once all of the filler has solidified you can now use sanding tools to smoothen it over hiding where all the holes, gaps

and seams are. Repeat step 7 and 8 until you're happy with how it looks.

(Note: This is the most time consuming step but the more care you put into it the better the finished result will be.)

(See ex 5, ex 6, ex 7)

Step 9

When you're satisfied with the shape of the filled areas wipe down all of the dust on the shell, clean off all of the faces and gaps. Once it has dried you will then spray it over with a primer, this is where the quality of work will shine as it will make the whole shell the same colour making it easier for your eye to see any imperfections.

(Note: Spray a light coat roughly 20cm away from the surface)

Step 10

If everything looks good then you can apply your finishing paint. However if you do notice any imperfections this is the last chance to fix them before paint, just repeat the last few steps until you're satisfied.

Step 11

When everything has dried the last thing to do id to attach the new bumper, it is easier to mark the holes and drill them on the bumper then use it as a template as you can gauge the space between the bumper and cyclotron easier. Once the screws are in place you have completed your conversion.