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Who you gunna call?
Following the theme of fire from 2023's wizard staff, the costume of choice for 2024 was Ghostbusters. Mainly because I figured I could turn the proton pack into a flamethrower.
I built the previous costume accessories, custom staffs, in just six days. This year I wanted to make sure I had adequate time for a more complex build, so the design work started just over 4 weeks before Halloween.
The frame is constructed from a simple PVC pipe, with the top assembly repurposing a bubble gun housed in a custom 3D printed enclosure. Integrated into the design is a high-voltage arc, and a propane line.
The handle lower on the staff contains control switches and buttons for operating the various effects, including a button at the base of the staff that activated the spark when it strikes the ground, creating a burst of light and sound.
Wand Design
The electronics in the wand handle were designed to keep controls easily accessible, while maintaining a compact layout. One switch activated both the main power and the lighting effects on the back of the pack, while the other controls the flashing filter canister and built-in fog machine. For safety, the propane delivery and ignition system were kept entirely manual, using two separate valves. This configuration allows the fuel line to be depressurized and provides an additional method of control over propane flow.
The wand design went through several iterations, starting with a compact, rounded housing and evolved into a more angular layout that better fit the steel tube on the torch.
The final housing is more comfortable to hold, structurally stronger, and better suited for organizing the ignition and propane systems.
Rev 1 design for wand housing
Final version of wand housing
The proton pack was fully modeled in OnShape to plan part placement, wiring paths, and mounting points. Once finalized, the entire assembly was 3D printed, painted, and fitted with accessories including lighting, hoses, and the wand mount. An ESP32 microcontroller was used to power custom lighting effects, adding interactivity and detail. The final build was fully functional, wearable, and a huge hit at Halloween parties—especially when showing off the lights and flamethrower.
Full assembly design in OnShape
Full assembly printed, painted, and with accessories
Pre-paint test fit
Snapchat-509932359.mp4Active lighting in-progress
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