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  1. Geohazard's Avatar
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    Jan 31, 2013, 6:46 AM - More Cheap & Cheerful Star Wars Blaster Replicas #1

    So, I've been inspired by Badsprout (and a limited budget) to produce a Merr-Sonn Power-5 Blaster as cheaply as possible.

    Original thread: http://www.therpf.com/f9/cheap-cheer...mauser-100493/

    I went onto everyone's favorite Internet auction site and bought (for $0.01 and $8.99 S/H) a plastic airsoft Mauser, which, if I was going to play airsoft would no doubt be a worthless piece of junk, but should fit the bill nicely for a knockoff blaster. Not as cheap as 99p, but it'll do.

    I'll post more pics as progress allows.
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  2. Geohazard's Avatar
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    Feb 3, 2013, 8:25 AM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #2

    So I still haven't received the airsoft mauser yet, but I went ahead and went looking for suitable cheap parts to make up the greeblies.

    1) power steering fluid funnel $1.49
    2) 1/2" close sch40 pvc nipple $0.37
    3) assorted washers $1.30 (had to buy smallest size in bulk)

    I'm going to slice the pvc nipple in half, and hopefully have two salvageable halves to attach to the sides for heat sinks. I still haven't figured out what to do for the one under the barrel. I plan to cut the funnel off at a suitable length and drill the holes for the flash hider.

    I'm not quite sure what I'm going to use to enlarge the barrel or connect the funnel to.
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  3. Badsprout's Avatar
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    Feb 3, 2013, 5:38 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #3

    Hi Geohazard. I only ever did the one Merr-Sonn, so I'll be interested to see how this build goes, especially as your base Mauser is a lot better than the piece of tat that I used. Best of luck.
  4. DrMcoy's Avatar
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    Feb 4, 2013, 11:31 AM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #4

    sorry - duplicate post
    Last edited by DrMcoy; Feb 4, 2013 at 11:37 AM.
  5. DrMcoy's Avatar
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    Feb 4, 2013, 11:35 AM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #5

    if you wanna spend another $15, you might order this and cut off the barrel and use it on yours:

    Han Solo Star Wars Gun, Han Solo Blaster - OfficialStarWarsCostumes.com

    video of same item modified:

    Han Solo Blaster Mod - YouTube

    Star Wars Han Solo ANH DL-44 Pistal Prop Blaster Review - YouTube
  6. Geohazard's Avatar
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    Feb 4, 2013, 6:39 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #6

    I'm looking into getting some DL-44's for future builds if this one works out well. What I'm trying to do here is make the build as best as possible on as little funds as possible. I'm shooting for under $25.
  7. TazMan2000's Avatar
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    Nov 2009
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    Sherwood Park, Alberta, Canada
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    Feb 4, 2013, 9:00 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #7

    DrMcoy said: View Post
    if you wanna spend another $15, you might order this and cut off the barrel and use it on yours:

    Han Solo Star Wars Gun, Han Solo Blaster - OfficialStarWarsCostumes.com

    video of same item modified:

    Han Solo Blaster Mod - YouTube

    Star Wars Han Solo ANH DL-44 Pistal Prop Blaster Review - YouTube
    Inexpensive yes, but I would think that most would be disappointed in how the sight is melded into the blaster making it very toylike...which is exactly what it is. It would take a bit of work separating it and making it look less like like a toy and more like a movie replica.

    TazMan2000
  8. Geohazard's Avatar
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    Feb 4, 2013, 10:45 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #8

    TazMan2000 said: View Post
    Inexpensive yes, but I would think that most would be disappointed in how the sight is melded into the blaster making it very toylike...which is exactly what it is. It would take a bit of work separating it and making it look less like like a toy and more like a movie replica.

    TazMan2000
    What I'd like to do for my next pistol replica project is actually get a Denix broomhandle and a .22 sight.

    Sadly, right now, this project is on hold temporarily, as the tracking info on my airsoft gun seems to indicate a misdelivery. At least it is now in the same county.
  9. Geohazard's Avatar
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    Feb 5, 2013, 11:37 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #9

    The airsoft Mauser arrived today!

    So on the list of things to do tomorrow:

    1) Sand marks/mold lines off of Mauser
    2) Glue code disc greeblie washers together
    3) Measure, cut, drill, & sand wooden dowel for flash hider
    4) Sand marks off pvc nipple and cut it in half
    5) Measure cuts and drill holes on funnel, cut & fit to wooden dowel
    6) Drill holes for LED greeblies, fit LED's

    Still yet to locate:
    Greeblies for the front heat sink & sight
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  10. Geohazard's Avatar
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    Feb 7, 2013, 1:41 AM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #10

    I didn't get as much work done today as I would have liked however having the right tools for the job instead of having to make do would have been stellar.

    First up, I figured out how to take apart the airsoft (so many little screws!), disassembled it, and inventoried the parts. I was delighted to discover that the grips are removable, which will make painting them later with a wood-effect considerably easier. I used a dremel to slice off the little cylinder that keeps the hammer from going flush, and cut out a notch for the hammer to rest in. While I was at it, I removed the stupid static safety switch, and smoothed out the cut with sandpaper.

    Secondly, I sliced the PVC nipple in half with the dremel, sanded the edges and the "Made in China" lettering down real smooth, and fitted it to the sides of the airsoft.

    Third up, I cut the funnel, dowel, and barrel, shaped them, and fit them together. Much help was my roommate who worked on reaming the wood part of the flash hider so I could take a food break.

    Yeah, I know, I knicked the dowel with the circular saw, the cone is a bit small, the angle isn't quite right, and the drilled holes are a bit wonky, but it has the right look to it. I think I'm going to look for a different funnel to use for the flash hider; one with a more obtuse angle to it.

    Speaking of, does anyone have any tips on how to get rid of the little bits of waste plastic that stick in the holes when you drill? I was using a tiny bit to ream, but that really wasn't getting me anywhere.

    Back at it tomorrow!
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  11. Badsprout's Avatar
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    UK
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    Feb 7, 2013, 3:51 AM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #11

    I use a small round file to clean up the flash hider holes on the Rubies DL44.
  12. Geohazard's Avatar
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    Feb 9, 2013, 1:16 AM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #12

    I've been considering how to fill out the heat sink greeblie on the sides of the blaster, instead of just the PVC, and had a bit of an epiphany while shopping for donor funnels. There was a funnel with a flexible plastic hose that should be suitable for the cone of the flash hider, as well as an intermediate sized piece to fit to the PVC. While at the auto parts store I also discovered a GM panel fastener which might be suitable to close off the open ends of the hose. The only problem I can see in this plan is how to effectively slice the small pieces in half. I think I'm going to invest in a modeling saw.
    Replacement funnel: $2.59
    Fastener greeblie: $2.49
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    Last edited by Geohazard; Feb 10, 2013 at 10:07 PM.
  13. thd9791's Avatar
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    Feb 9, 2013, 11:27 AM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #13

    This is really cool, I have the same airsoft, and never took it apart...lol maybe I should - your pics are really informative, thank you!
  14. Geohazard's Avatar
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    Feb 9, 2013, 2:41 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #14

    thd9791 said: View Post
    This is really cool, I have the same airsoft, and never took it apart...lol maybe I should - your pics are really informative, tha.nk you!
    If and when you do, I would recommend getting a magnetic dish to hold all of the little screws in. They are very easy to lose track of.
  15. thd9791's Avatar
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    Feb 10, 2013, 5:50 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #15

    good idea thanks!
    Geohazard said: View Post
    If and when you do, I would recommend getting a magnetic dish to hold all of the little screws in. They are very easy to lose track of.
  16. Geohazard's Avatar
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    Feb 11, 2013, 11:01 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #16

    More work done tonight:
    1) Used hobby saw to cut hose and GM greeblies for heat sinks
    2) Drilled holes for/fitted green & red LED's
    3) Glued Imperial greeblie together
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  17. Geohazard's Avatar
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    Feb 12, 2013, 11:16 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #17

    More work tonight:

    1) Spot-filler to fix assorted dings and scrapes.
    2) Re-did flash hider cone from donor-funnel. Decided not to mess with drilling holes, and therefore not having to do all that work cleaning the plastic out.
    3) Dremel-work to shape flash-hider cylinder, sanding.
    4) Glued two halves of power-pack, and greeblies in place.
    5) Fit flash hider pieces together.

    Tomorrow, I hope to get everything fit together, fill gaps with spot putty, put a few layers of primer on, maybe get the wood effects on the grip started, and put in some lead for weight.
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  18. ginyu force's Avatar
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    Feb 12, 2013, 11:34 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #18

    Geohazard said: View Post
    More work tonight:

    1) Spot-filler to fix assorted dings and scrapes.
    2) Re-did flash hider cone from donor-funnel. Decided not to mess with drilling holes, and therefore not having to do all that work cleaning the plastic out.
    3) Dremel-work to shape flash-hider cylinder, sanding.
    4) Glued two halves of power-pack, and greeblies in place.
    5) Fit flash hider pieces together.

    Tomorrow, I hope to get everything fit together, fill gaps with spot putty, put a few layers of primer on, maybe get the wood effects on the grip started, and put in some lead for weight.
    wow, this is great stuff, i was looking for a way to make the flash hider and you have done it for me!! I too am making a Han blaster, but i am making the "Greedo Killer". And here are the components i have purchased so far.

    scope:
    Amazon.com: Tasco Rimfire 4x 15mm Crosshair Reticle Riflescope: Sports & Outdoors

    Nuts to hold mounting bracket on:
    Amazon.com: Tripod 1/4 inches Screw to Flash Shoe Mount Adapter: Camera & Photo

    The gun i will be using:
    Amazon.com: New Airsoft C96 Mauser Pistol Han Solo: Sports & Outdoors
  19. Geohazard's Avatar
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    Feb 13, 2013, 7:59 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #19

    Found out the hard way that my glue bonds plastic to wood instantaneously. So now I need a new barrel and a flash hider cylinder. I'm thinking this time, pvc.
  20. Member Since
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    Feb 13, 2013, 8:04 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #20

    I can't wait to see he finished product!
  21. thd9791's Avatar
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    Feb 13, 2013, 9:13 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #21

    looking fantastic, we all have setbacks, just try again - we learn from every mistake!
  22. "Don't be a fool" RPF Premium Member Cenobyte's Avatar
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    Feb 13, 2013, 9:57 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #22

    Geohazard,
    I ordered a few of the plastic ones to find out that they were maybe 3/4 scale

    Are yours 1:1?

    I ended up picking up 2 Denix mausers also.

    If they are 1:1, would you mind possibly pm'ing me the seller Id on eBay here please?

    Thank you,
    Brandon
  23. Geohazard's Avatar
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    Feb 13, 2013, 10:33 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #23

    Thanks for all the encouragement guys!

    I went down to the Home Despot this evening and found some potential replacement parts, in the form of a short length of 1/2" copper tubing and a PVC reducer slip coupling. I haven't figured out how I'm going to attach the coupling to the barrel yet, as there is plenty of wobble room between the id of the coupling and the od of the tubing. I've a few ideas, spot putty, chemical A+B foam, or modeling clay.

    I also found some suitable plastic greeblies to modify & attach to the other side of the airsoft, and I'm going to use a bit of zip-tie and some spot putty to add a non-functional stun/kill switch in the correct position. Hooray for random greeblie finds!

    Also grand is the copper tubing is a perfect fit to where the plastic barrel would have gone, without having to do any modifications!

    No more work tonight. I've got a bit of a headache coming on, and the glue and spot putty needs time to cure before priming.
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  24. Member Since
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    Feb 14, 2013, 9:24 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #24

    Excellent work so far! Keep it up!
  25. Geohazard's Avatar
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    Feb 14, 2013, 9:52 PM - Re: More Cheap & Cheerful Star Wars Blaster Replicas #25

    Thanks Bru!

    We're now on the downhill stretch. I got a lot accomplished today, as far as getting greeblies and things mounted. Things are starting to get a bit more expensive, and I'm far over my budget of $25, but now I have some of the materials on hand, for the next project.

    Today's materials:
    Walnut tone spray: $8.13
    5yd 12-gauge Aluminum Floral Wire: $2.39
    Black Sculpy Clay: $1.29

    1) Sanded & primed grips. It looks like the Rustoleum primer I'm using sticks to the plastic just fine, and one coat is good enough!
    2) Cut, sanded, & drilled small dowel bit for the "scope". Glued to the airsoft.
    3) Twisted Al wire around 1/2" Cu-tubing, trimmed edges to fit placement for "scope power cord". I wanted something a bit more rigid than your average curly-cord, and this stuff works great.
    4) Filled PVC reducer with clay, cored to od of 1/2" Cu tubing. Baked in oven at approximately 275° F for about 12 minutes (the directions on the clay said 15 mins per 1/4" of material). Unfortunately, I found out that PVC shrinks during this process. The Cu-tubing no longer fit inside the core. No problem, that's what Dremels are for!

    ***Be careful when cutting/grinding/heating PVC! Chlorine gas is no fun!***
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    Last edited by Geohazard; Feb 20, 2013 at 11:13 PM. Reason: Added Safety Warning

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