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  1. Lichtbringer's Avatar
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    Aug 4, 2010, 8:58 AM - Han Solo ESB + ANH all metal Blasters, step by step #1

    from Star Wars, DL-44, off course.
    I needed a break from doing the cinema, so i decided to do something completly different - good old metal-work.

    First i had some plans printed in 1/1:


    The next needed thing was a Mauser, prefered a metal-replica from Denix:

    (Barrel shortened, frontsight was sawed off)

    Disassemling and modifying it, drilling and tapping the magazine for the scope-mount screw.
    Then using the lathe to modify a knurled fastener, and to produce a 1/8" thick plastic-spacer with the same diameter:



    Overall shot:


    Next job was turning a flash hider - custom, not any one from the show, just for the fun and the practice:


    Here it is:


    Yesterday the next original parts arrived. Now i have to decide if i go for all-metall and turning some on the lathe - or make some molds and cast them from resin:


    Some more made parts:



    For the next blaster (they used 6 different versions in the 3 movies - still some work to do):


    Im still hunting for the right scopes and some other parts.
    Last edited by Lichtbringer; Oct 28, 2010 at 9:34 AM.
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  3. HeroWorship's Avatar
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    Aug 4, 2010, 9:42 AM - Re: Blasters #2

    Just beautiful! Wish there was a vid so I could see you actually make these parts.
  4. Lichtbringer's Avatar
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    Aug 4, 2010, 10:38 AM - Re: Blasters #3

    HeroWorship said: View Post
    Just beautiful! Wish there was a vid so I could see you actually make these parts.
    Thanks.

    Well, not much to see there - no hot chick in a bikini in my shop.

    Only a man in the 40s with wide hips, working on a small lathe and a drill press.
  5. RPF Premium Member GeneralFROSTY's Avatar
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    Aug 4, 2010, 2:18 PM - Re: DL-44 - metal Blasters #4

    Would you be offering a run of the upgrade parts in the JY at any point??
  6. RPF Premium Member RoCKo's Avatar
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    Aug 4, 2010, 2:57 PM - Re: DL-44 - metal Blasters #5

    id be in too! please let me know when your doing a run!

    amazing work, i want to do a DL-44 some day too and this is very inspiring!
  7. Lichtbringer's Avatar
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    Aug 4, 2010, 8:28 PM - Re: DL-44 - metal Blasters #6

    Run? Upgrade parts? Im not sure what parts youre asking about.

    I have no access to a cnc-machinerie company, what would be needed for many equal pieces of one kind with a good and constant quality, in a acceptable timeframe.

    Im just doing some individual pieces for "my personal blaster", for the fun of the hobby/building - my flash-hiders from the movie guns i planned to find a company which machines them. For them there is equipment needed that i dont have.
  8. Lichtbringer's Avatar
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    Aug 11, 2010, 4:50 PM - Re: DL-44 - metal Blasters #7

    I made a new flash-hider



    This is for my own idealized blaster, the movie-replicas will be more accurate. I like the sleeker look, but im not completly sure which version i like more.



    While searching my greeblie-box i found some really old bump-ons, which might work for the rotj- version.



  9. Prefect42's Avatar
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    Hotel California, LA.
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    Aug 12, 2010, 1:34 AM - Re: DL-44 - metal Blasters #8

    Mighty fine work there, Lichtbringer. Looking forward to more pictures.

    It's fun to see a DL-44 with artistic interpretation.

    Ted.
  10. Lichtbringer's Avatar
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    Aug 12, 2010, 9:00 AM - Re: DL-44 - metal Blasters #9

    Prefect42 said: View Post
    Mighty fine work there, Lichtbringer. Looking forward to more pictures.

    It's fun to see a DL-44 with artistic interpretation.

    Ted.
    Thanks, Ted.

    Sure, i will do the others, the "real" ones, too - but i like the idea to have my "own" displayed with them.
  11. Lichtbringer's Avatar
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    Aug 12, 2010, 9:39 AM - Re: DL-44 - metal Blasters #10

    HeroWorship,

    you asked for a vid. I have no vid from the process, but maybe some pics are good too?

    This is my shop, you see the machines are small - usually i use them for model making, mostly for styrene.



    Thats the way the material looks before


    Turning a flash-hider




    For fabricating the ANH-fasteners from above i first put a threaded rod in the chuck



    With the fastener on it, before any work


    Making the "step" on the backside


    Turn it over to the other side



    Turning the inner step



    The slighly smaller version for the middle fastener



    These are the genereal stages when turning something new: Putting some slighly oversized raw-material in the chuck


    Turning the front to make it smooth/flat


    Turning the sides to the needed diameter


    When having no cnc, the most important part - measuring. Better one time to often than not enough.


    Flipping the piece, and turning the part that was in the chuck to the same diameter as the ready part


    Nearly ready - just a little bit to long. Thats for more comfortable working, has to be turned down to the right length in the last step


    This might give you a guess what it will be in the end



    Its no vid, but it might help to understand what has been done to make such parts. My main problem is the size of the machine, it is capable of metal work, but only in many smaller steps than a 2 ton lathe in a professional workshop. So i need a few hours for a flash-hider, on a big lathe it could be done in half an hour, and on a cnc in some minutes.
    But for my small stuff from time to time this is enough.

    I hope everyone had some fun time while watching these.
  12. IFA is offline
    IFA
    IFA's Avatar
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    Aug 12, 2010, 12:27 PM - Re: Han Solos DL-44 - metal Blasters #11

    Nice work on the revell pistons !!!!
  13. Member Since
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    From
    Slidell, LA
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    Aug 12, 2010, 12:33 PM - Re: Han Solos DL-44 - metal Blasters #12

    Awesome job man, cant wait to see it finished!
  14. Lichtbringer's Avatar
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    Aug 12, 2010, 12:58 PM - Re: Han Solos DL-44 - metal Blasters #13

    Thanks, guys.

    I will post pics as soon as i have something new to show.
  15. Don93's Avatar
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    Tennessee
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    Aug 13, 2010, 6:04 AM - Re: Han Solos DL-44 - metal Blasters #14

    Very cool, especially the home metal working.
  16. RPF Premium Member jediscout's Avatar
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    Aug 13, 2010, 9:18 AM - Re: Han Solos DL-44 - metal Blasters #15

    Ditto. Really enjoyed seeing the In Process shots. Very cool pics!
  17. Lichtbringer's Avatar
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    Aug 13, 2010, 3:05 PM - Re: Han Solos DL-44 - metal Blasters #16

    Many thanks for your nice comments.

    As there are really some out there who like this kind of "making of", i will try to show the process as good as i can.


    Ive sawed the turned pistons in half


    The problem with cutting is ... you loose material where the saw works. You have to choose between a little bit on both halfs, or one perfect half and one thats a little bit smaller. I choosed to have a perfect for the ESB, and a not completly perfect for my version. Its not that much difference, 1mm, you only notice it when you know it. I used and ruined a etched Zona-saw to get a thin as possible cut - sadly they are not here available, i need to order a new in the US.


    Next part was milling the slots




    I think i can live with the result


    And attached to the gun, this is the "not perfect" half




    There is not so much left i can do on this blaster now - mainly im waiting for the ordered M19. There are some small greeblies on the left side i have to make, but up to now i made no decision if i do them in metal or plastic.
  18. Hirohawa's Avatar
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    Aug 13, 2010, 7:03 PM - Re: Han Solos DL-44 - metal Blasters #17

    Awesome work!
  19. philip7's Avatar
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    Aug 14, 2010, 12:48 AM - Re: Han Solos DL-44 - metal Blasters #18

    great work, will you makin and sellin these ?
  20. cosmic_x's Avatar
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    Aug 14, 2010, 5:16 AM - Re: Han Solos DL-44 - metal Blasters #19

    Wow, Michael this is awesome, and I was wondering what you are up to these days

    habe gerade gesehen, wrdest du auch eine fr mich machen
  21. Lichtbringer's Avatar
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    Aug 14, 2010, 6:02 AM - Re: Han Solos DL-44 - metal Blasters #20

    Thanks to all of you.


    Philip 7, im afraid i will not. As i explained earlier, my machines are to small to deliver a run in a acceptable timely manner - it would take too long, and would be to expensive if calculated on a "x money per hour"- basis. For such a job a CNC-machine-shop is needed to produce the parts with reasonable prices.
    And i believe the name "Lichtbringer" is a good one in the SW scale modelling world, i dont take the risk to ruin it with such a try.

    Sorry, i hope you understand.


    Hi Kostas,

    i was burned out at making Starship-kits (to many on my "have to do"-list), i had no drive to do anything kit-related for months. Everytime i tried, i sat at my workbench and stared at the waiting styrene ...... and was bored, even before starting.

    I needed to start something new, something i havnt done before - something thats a new challenge for me. So i first made a big step at finishing my Enterprise-homecinema (not ready yet, but a mayor step), and then i started these blasters.
  22. cosmic_x's Avatar
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    Aug 14, 2010, 6:16 AM - Re: Han Solos DL-44 - metal Blasters #21

    and the blasters look very good, wouldnt expect otherwise from you
  23. Lichtbringer's Avatar
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    Aug 14, 2010, 6:27 AM - Re: Han Solos DL-44 - metal Blasters #22

    Having nothing i can do at my own version atm., i startet the ANH-one.

    First drilling and tapping the bar


    Then disassembling the Mauser and drilling/tapping the body of the gun.


    Next was screwing a bolt in - cut to length, and secured with loctite "strong" (be sure it has the correct length before using loctite). I always use the cut side where it it not visible.


    In the time the loctite needs to harden, i ensured a proper fit with fixing it with the machined fasteners on the bolt, and a long screw in the other hole.


    The same procedure with the other bolt. As the material of the mag is much thinner, i beefed it up from the inside with a nut.


    Cutting and securing the middle bolt - and again the use od loctite "strong" (i use it on all bolts, but not on the fasteners - for the later dissassembly for painting).


    And again, securing it for a proper alignment with the fasteners, for the time the loctite needs to harden.


    And ready is the lower part of the mount.


    Now i have to to a search for the missing ANH-parts. Metall would be prefered, but first class resin-casts (as a starship builder i cant accept crappy casted parts) are OK, too.

    I think CE is the way to go, resin-related? Or Droopydoos?
  24. Lichtbringer's Avatar
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    Aug 14, 2010, 6:29 AM - Re: Han Solos DL-44 - metal Blasters #23

    cosmic_x said: View Post
    and the blasters look very good, wouldnt expect otherwise from you
    Thats a pretty kind way to say im a nitpicking old german.

    Thanks, my friend.
  25. Member Since
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    San Diego, CA
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    Aug 14, 2010, 5:24 PM - Re: Han Solos DL-44 - metal Blasters #24

    Damn, that's beautiful work!
  26. TI6815's Avatar
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    Hamburg /Germany
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    Aug 14, 2010, 6:51 PM - Re: Han Solos DL-44 - metal Blasters #25

    Sehr cool mein Freund
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