The pack is a mixture of GB1 and GB2 elements. About 90% of the pack is constructed from 1/8"-thick hardboard, which is very lightweight but very sturdy. All of the hardboard pieces were cut by hand with an Xacto blade (a very arduous task but I didn't have a jigsaw or bandsaw). The boxes which had rounded corners (gearbox, powercell, gun-mount, etc.) were constructed from 1/2"-thick pine. I rounded those corners by hand using a Black&Decker rotary sander. The rest of the pack's basic shape was achieved with poster board, PVC pipe, and wooden dowels.

Each component of the pack was painted and sanded individually. For each component I applied 2 coats of primer (sanding after each coat) and then applied 1 or 2 coats of Rustoleum Ultra Flat Black. To achieve the realistic weathered effect, I sanded appropriate corners and edges of the black coat until the primer started to show through. I was very pleased with the finished product. Because I was balancing a family and a job while I built the pack, the entire construction took about 7 months.