The solution was to go with an ultracite reactor. After two months of fruitless experiments, Frost's team had to go for broke. Although the team continued to experiment with new solutions as late as May 2076, they were already way past specifications on the repurposed T-45 reactor, causing overheating and stability issues. Although using titanium solved the durability issues, the suit's extra weight made a more efficient reactor necessary. Although too expensive for the T-45 power armor due to the expense of the mining process, it was considered an acceptable choice for a corporate design. The material had the necessary tensile strength to keep the arm components from tearing themselves apart. By September 2075, the research team settled on using black titanium, native to Appalachia.
The extra punishment the arm units took when boring into bedrock caused micro-stress fractures and sheared gear assemblies. As the Excavator was intended for mining, not combat, durability issues manifested quickly. The project made headway at first and Frost was confident he could deliver a prototype within months. Frost welcomed the private sector job, with little oversight and reporting required as long as he showed results. Formally named the EX-17 Excavator, the power armor project was headed by Harold Frost, siphoned off directly from the United States Army Research Corps in early 2075. Developed by Garrahan Mining Co., the "Excavator" class of Power Armor never saw full production, despite being heavily advertised in Appalachia as the future of mining.
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