TFA Functional Belt Boxes build tutorial

[ukswrath[Staff]]

In this tutorial I'll be making the right two vertical belt boxes functional at the same time maintaining visual and mounting requirements

 

NOTE: This is obviously optional, not mandatory.

NOTE: Also, I suggest performing this procedure only after the boxes are ready to mount on the belt (fully assembled except for attaching front and rear sections) prior to painting.  

 

Objective:

To create a inner bracket system securing the front box cover to the rear back plates allowing the boxes to become functional. 

 

Steps:

1. Measure the distance between the front box inner wall to the back plate inner wall. Subtract the front and rear section plastic thickness.

2. Subtract the thickness of the Velcro 

3. Create brackets. 3b. Bend brackets (Velcro mount)

4. Cut and adhere Velcro to brackets and backplate

5. Test fit

6. Glue brackets to inner side of front box

7. Final check

 

Material:

2"x5" Cover strip material (or similar)

2"x2" White Industrial Strength Velcro (or similar)

CA glue & Zap-A-Gap

 

Tools:

PPE (Safety gloves & glasses)

Exacto knife

Steel Ruler

Head gun

Wood (or similar)

 

 

These are the boxes that will be reconfigured 

 

 

 

1. Start by measuring the overall depth of the small and large, right, vertical boxes (with or without the back plate, it doesn't matter). 

NOTE: Depending how you trim your boxes your measurements may vary from mine. The depth of my boxes are a couple mm short of the once molded return edge.

 

1a. Subtract the plastic thickness of the front boxes and rear back plates NOTE: The plastic thickness is about 1mm, maybe 1.5mm

 

Small box measured 18mm (the camera is a bit off in the image). Subtracting the plastic thickness I ended up with a 16mm distance between the front box inner and back plate inner walls.

 

 

 

Large Box measured. 31mm. If you assembled the top portion of the box you'll need to take into account the plastic thickness in that area, which could be 2-3mm. Subtract the 1mm for the back plate and you have approximately 28mm distance between the front box inner and back plate walls.   

 

 

 

2. Measure Velcro thickness - Using Velcro brand, 2" wide, White, Industrial Strength the thickness was found to be 4mm.

 

 

 

2a. After subtracting the Velcro thickness (4mm) the brackets will need to be the following lengths:

 

Small box bracket - 12-13mm

Large box bracket - 23-24mm

 

 

3. Cutting the Brackets - NOTE: Take the overall length of the bracket (above) and add 7-9mm. We are going to heat and bent this section to be used for the Velcro mount.

Using cover strip material or something similar in strength, measure and cut the brackets accordingly. 

 

Width - 50mm or 2"

 

 

 

Length - 

 

Small box bracket - 13mm

Large box bracket - 24mm

 

 

 

3a. Cut into sections.

 

 

 

3b. Bend brackets. In this section It is best to have a vise or bench clamp you will need both hands free. 

 

Using a straight edge scribe the plastic once with a exacto knife at the bend line. Though not absolutely need it will assist in the bending.

 

 

 

Place plastic between two pieces of wood (preferably with 90 degree corners) exposing the 7mm section. Leave around 1mm above the woods edge.

 

 

 

 

Evenly heat the exposed section for about 10-20 seconds, or until pliable.

 

Note: Have a third block of wood or something similar ready to do the bending. 

 

 

 

Using the 3rd block of wood fold over. Hold for about 10-20 seconds.

 

You should be left with this.

 

 

 

Measure to ensure the overall length is correct.

 

Small box

 

 

4. Measure, cut and adhere Velcro to back plate and bend on bracket.

 

Cut Velcro to 10mm in length.

 

 

 

4a. Adhere hook side of Velcro to back plate. 

 

When installing the Velcro on small box it will be placed at the top and bottom sections edges near the return edge. 

 

 

 

When installing on the large box place the Velcro about 2-3mm from the return edge on the rear back plate to account for the step in the front box.

 

 

 

It should look similar to this when finished.

 

 

 

4b. Adhere loop side to Velcro to Bracket 

 

 

 

5. Test fit before gluing

 

Test fit the assemblies prior to gluing especially since you don't have any extra boxes in case you mess something up, right?

 

Attach brackets to back plate via the Velcro.

 

Small box 

 

 

Assemble

 

 

 

Large box 

NOTE: Remember to take in account for the front box step.

 

 

 

Success! Moving forward.

 

6. Gluing

 

Remove back cover. Apply CA glue to bracket base.

 

NOTE: Ensure the glue is only on the bracket mounting edge. Anywhere else you may inadvertently glue the back plate to the box.

 

 

 

 

Carefully assemble

 

 

 

Spray Zap-A-Gap around edges to accelerate the cure times in case glue may be spreading to areas it shouldn't.

 

Small box

 

 

 

Large box

 

 

After dry remove back plate.

 

 

 

 

At this point I suggest applying more glue to the mount area.

 

 

 

Finished!

 

Edited September 14, 2015 by ukswrath

[ukswrath[Staff]]

I just realized I have posted this in the wrong section, my bad. Move it if you need to.

[captsafe66[Admin]]

Moved.

[Dark PWF[Staff]]

Beautiful work Tony!  

 

I expected no less from you when you said that you were going to attempt this.  Thank you!

[ukswrath[Staff]]

Beautiful work Tony!  

 

I expected no less from you when you said that you were going to attempt this.  Thank you!

 

Thanks Tim 

[Haribon72[TK]]

Awesome Tony!

[gmrhodes13[Staff]]

Nice work could also use hinges and magnets

[Paul.kennedyjr[TK]]

I was just discussing this at the last troop I was on. I'm so glad you posted this.

 

 

Sent from my iPhone using Tapatalk

[SolderMaster]

Well done, Sir!

[ukswrath[Staff]]

Awesome Tony!

 

Thanks my fellow garrison trooper 

[ukswrath[Staff]]

Nice work could also use hinges and magnets

 

My first thought was magnets then I recently wiped my discover card because it got too close a magnet, hinges is a good idea also. Actually all you have to do is pull the top portion of the box open and the lower velcro stays intact 75% of the time anyways, I guess that's a decent hinge. Thanks Q.

 

BTW I need to post my mini gun on your thread. Excellent idea. 

[ukswrath[Staff]]

I was just discussing this at the last troop I was on. I'm so glad you posted this.

 

 

Sent from my iPhone using Tapatalk

 

Enjoy!

[ukswrath[Staff]]

Well done, Sir!

 

Even after all the flack I've given you the last couple days, I am humbled. Thanks Brian

[SolderMaster]

Even after all the flack I've given you the last couple days, I am humbled. Thanks Brian

I give credit where credit is due. To make a tutorial THAT detailed takes time and passion. You, Sir, have my respect.

 

You can't teach passion. Something I've learned over the years. Those of us who truly care about troopers helping troopers, will find a way, no matter how delayed (me), to bring information, knowledge, or nun-chuck skills so everyone else can benefit. Love this detachment!

[ukswrath[Staff]]

I give credit where credit is due. To make a tutorial THAT detailed takes time and passion. You, Sir, have my respect.

 

You can't teach passion. Something I've learned over the years. Those of us who truly care about troopers helping troopers, will find a way, no matter how delayed (me), to bring information, knowledge, or nun-chuck skills so everyone else can benefit. Love this detachment!

 

Well thank you again.

 

THT 

[Daetrin[Admin]]

Awesome tutorial - thanks for sharing

[ukswrath[Staff]]

Awesome tutorial - thanks for sharing

 

Thank you Paul, my pleasure

 

THT