Expanse Backpack Thrusters - minimal printed parts version

I created this to make the Thrusters that go on the Backpack of Belter space gear. My goal was to minimize printed parts and instead use hardfoam board and PVC pipe and print only the details. This way, less filling and sanding is required, especially on the pipes

The PDF file contains a Blueprint how the pieces should fit together which can also be used as a template to cut the required pieces.

What you'll need:
3mm thick Hardfoam board
DN36 PVC Pipe (around 39mm OD) - the type used to run cables through (Cut into two half pipes)
Screw-on U-bars for the vent guards + matching nuts
Glue of choice - Contact cement works great on hardfoam but you can also use superglue (which works good on the printed stuff)
Epoxy Putty for filling gaps and securing the U-bars inside

The 395 Cube is a little helper for making sure the side walls are glued perfectly vertical to the bottom parts and have the correct distance for the front and back panels to fit in.

All connecting hardfoam edges should be beveled/chamfered at a 45⁰ angle to get nice joints, however it could work without as well. There are 45⁰ degree cutting guides available on Thingiverse to help.