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  1. coryalex's Avatar
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    Jul 2012
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    Willcox, Arizona, United States
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    Feb 10, 2014, 10:40 AM - Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #1

    Well, I've decided that for this year's Phoenix Comicon, I'm going as the Team Fortress 2 Heavy.
    While I'm not quite built like the Heavy, I still think it's a good opportunity to build another fun 3D printed prop weapon. Last year, I built a Vera... but this year, I wanted to construct something with LIGHTS AND SOUND.


    I'm starting with the Barrel Assembly (the visually "cool" component). I've modeled everything from scratch based on various screenshots and artwork... there seems to be a lot of variation in this prop which will lend itself well to my own creative license.

    I do intend to include full sound with my light scheme. I'm in contact with someone to make me a custom sound ship which will include at the minimum sounds for:
    - wind up and run
    - firing
    - run
    - wind down
    *The prop will be wired to activate the motor and lights right along with sounds from the sound chip... I hope I can pull it off.


    I'm 3D modeling my special components in SketchUp and printing them in ABS plastic on my MakerBot Replicator.
    The Barrels will be made of 1" ID PVC pipe, and the shaft the assembly will spin on will be made of 1/2" electrical conduit.
    Rear of Barrel Assembly will consist of a 4" x 3" black PVC reducer coupling and 3" PVC pipe (with either a PVC cap or specially printed end cap on the back of the 3" PVC).
    1" (ID) PVC and 4" x 3" PVC reducer (reducer will house front bearing support for barrel assembly)




    My goals with the Barrel Assembly include:
    - making it spin easily (to be driven with a small motor)
    - installing 12v yellow LED lighting at the end of each barrel
    - making the LED lights fire in sequence as the barrel assembly spins (uppermost LED will "fire" as it passes top position)


    So, without further delay, here is my progress, thus far.


    Flash Hider




    Spacer (2 of these prints will be affixed back-to-back... 2 full Spacers needed)



    Wide Ring (2 of these prints will be affixed back-to-back, center hole is for 1/2" electrical conduit shaft)



    Rear Ring (center hole is for 1/2" electrical conduit shaft)









    Light Holder



    Printed Light Holder



    Tabs on back will have wire soldered directly



    LEDs fit flush with surface of "plug"... plug will be slightly recessed in 1" PVC



    Printed Lot of Light Holders with yellow LEDs installed





    Light Connection (fits in the back end of each of the 6 barrels)




    Copper Wire to be used for "feet" to make connection to the braided cable in the front bearing holder as the barrel spins









    Front Bearing Holder



    Rear Bearing Holder



    Printed Front and Rear Bearing Holders (with 3D printed bushings to adapt the 3/4" ID Bearing to the OD of the 1/2" Electrical Conduit)



    Front Bearing Holder fits right into 4" x 3" PVC adapter



    Shown with steel braided cable and printed bushings









    Here's a group of barrel items printed



    300 RPM high-torque 12v motor... I need to model and print a pulley for this motor and the barrel shaft (1/2" conduit)... 1:1 Ratio will likely be right





    That's it, so far. I'll publish more as I get more done.
    Wish me luck!
  2. Member Since
    Feb 2014
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    Feb 10, 2014, 3:26 PM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #2

    As I scrolled I found myself hoping more and more that you'd have pictures of it firing. It's looking good though!
  3. Haystack Hair's Avatar
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    Jan 2012
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    Brighton, UK
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    Feb 10, 2014, 3:30 PM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #3

    Subscribed, there's not enough TF2 on this board!
  4. coryalex's Avatar
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    Willcox, Arizona, United States
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    Feb 10, 2014, 3:38 PM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #4

    I do plan on getting everything test-fitted sometime this week so I can verify that my mechanism for operating the lights will function properly.
    I figure a dry test fit to verify this method will work is worthwhile... shame to put her all together and have her not work, right?

    Fun fact: I've been printing the large "flash hider" (flower pot shaped end of the barrel assembly) all day... it's been printing for 6 hours and 20 minutes... and it's only 53% done.
    (printing with 10% infill)
  5. coryalex's Avatar
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    Jul 2012
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    Willcox, Arizona, United States
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    Feb 11, 2014, 8:52 AM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #5

    Got the most iconic part of the build printed... finally.
    After fixing a few weird errors in my model, it printed flawlessly... in only 11 hours and 29 minutes!









  6. coryalex's Avatar
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    Jul 2012
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    Willcox, Arizona, United States
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    Feb 11, 2014, 9:00 AM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #6

    Just finished printing the first of 6 Electrical Connectors (26 minutes for one)
    This piece goes at the back end of each barrel to wire each LED to a copper "leg" which will ride around in a circular motion over the Front Bearing Plate... making contact during about 30 degrees of the rotation... providing for a rapid on/off for each barrel as they pass by the braided steel cable.
    I don't know if this technique has been used before, but I'm sure it's applicable in other props.



  7. skyconlb's Avatar
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    Oct 2012
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    Los Angeles, CA
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    Feb 12, 2014, 9:50 AM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #7

    Looking good! Loving the Breaking Bad action figure looming over the last pic!
  8. coryalex's Avatar
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    Willcox, Arizona, United States
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    Feb 12, 2014, 10:10 AM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #8

    Okay, I forgot to document some of the stock components I'm using.
    So that their size and availability is documented, here goes:


    LED pods - Cutequeen LED Car Lights Bulb Yellow T10 3528 4-smd 194 168 (T10 base, made of circuit board material)


    Barrel Bearings - Marathon Industries 60011 - 3/4" ID Replacement Precision Ball Bearings (1-3/8" OD)


    Drive Motor - Amico 300RPM 12V 0.6A High Torque Mini Electric DC Geared Motor (5.4 x 3.9 x 0.6 inches w/ 3mm shaft)


    Copper Wire - 1/16" solid copper wire


    Switches - I'll be using standard DPDT switches to activate lights/motor along with sound


    Battery - I'm planning on using 8 D Cell batteries to give me long life and free me from a charger... may change to LiPo pack... we'll see.
  9. coryalex's Avatar
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    Willcox, Arizona, United States
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    Feb 12, 2014, 12:49 PM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #9

    Progress made includes:
    - Printing Pulleys for the small 300 RPM Motor and Barrel Shaft (1/2" Electrical Conduit)
    - Test fitting the electrical wire and screws for the connections at each Barrel


    Here are photos for you to enjoy.


    Pulleys (small bore for Motor, large bore for Barrel Shaft)





    Yes, I do plan on using large o-rings (3 of them) to transmit power from the motor pulley to the shaft pulley... o-rings are flexible and fairly durable... we're not dealing with much stress or power transmission here.



    Electrical Connection Test Fit (one plug will fit in the back end of each barrel providing 2 copper "feet" which will make contact as they rotate, electrifying one barrel's LED at a time as it turns)






    Finally, here's a photo of all the items I've printed, acquired, or gathered for assembly of the Barrel.






    Even just laying there in pieces, she looks pretty menacing. I can only imagine the finished prop.
    I hope to do a complete dry-fit test this weekend to ensure proper rotation and operation of the electrical connection I devised... wish me luck. (I might even post a video link, if everything works properly)
  10. Haystack Hair's Avatar
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    Brighton, UK
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    Feb 12, 2014, 1:25 PM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #10

    Are you going to sand the lines out?
  11. coryalex's Avatar
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    Willcox, Arizona, United States
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    Feb 12, 2014, 1:49 PM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #11

    Haystack Hair said: View Post
    Are you going to sand the lines out?
    That's the plan. "Grain" artifacts from the layers printed on a hobby printer like mine are natural, but they sand out pretty well. Sandable primer is also your friend when treating 3D printed parts like this.
  12. Haystack Hair's Avatar
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    Feb 12, 2014, 1:51 PM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #12

    coryalex said: View Post
    That's the plan. "Grain" artifacts from the layers printed on a hobby printer like mine are natural, but they sand out pretty well. Sandable primer is also your friend when treating 3D printed parts like this.
    I meant mainly the 3D model style polygonal lines which break the curves up but I didn't make it very clear haha
  13. coryalex's Avatar
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    Feb 12, 2014, 1:55 PM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #13

    Haystack Hair said: View Post
    I meant mainly the 3D model style polygonal lines which break the curves up but I didn't make it very clear haha
    Ah, yes... that, too. The circles I like working with are 60-sided... rough enough to keep print times fast but fine enough that I can work them out pretty well with sanding.
  14. coryalex's Avatar
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    Feb 14, 2014, 5:14 PM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #14

    Made some dummy Hex Heads for one of the barrel rings



    Made a spacing bushing for the barrel assembly (separates the barrel from the front bearing)



    I decided the braided steel races needed to be raised a bit, so I made this biscuit...



    I'll trim, clean, and secure these later...



    I also modeled a secure mount for my little 12v 300RPM motor...
  15. Member Since
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    Feb 16, 2014, 6:21 PM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #15

    Coryalex I have been trying to reach you for months now, I sent you mail through fb probably sitting in your "other" folder, if you get this could you please contact me?
    Isaac Shamy.
  16. coryalex's Avatar
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    Feb 16, 2014, 9:04 PM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #16

    PM sent.
  17. coryalex's Avatar
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    Feb 17, 2014, 10:42 AM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #17

    After getting to work a few hours this weekend, I got the following done...


    Custom housing for 12v 300RPM motor




    Used JBQuik to secure steel braid




    Fabricated a "Y" connector out of PVC and JBQuik (for frame, later in build)



    Laid out barrel items for a dry test fit





    AND I FINALLY GOT TO SPIN THE BARREL (just a few components to see how heavy it was and to see how easily it would spin)
    I was amazed how easily it spun... my little motor should have no problem... hopefully. Now, I didn't have any of the electrical hooked up for lights or motor, but I will soon.
    Heavy Minigun barrel test 01 - YouTube


    As a pleasant distraction, I did spend some time finising up my Heavy Dolokahs build...
    http://www.therpf.com/f9/team-fortre...6/#post3211543
  18. coryalex's Avatar
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    Willcox, Arizona, United States
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    Feb 17, 2014, 1:12 PM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #18

    Oh, and I also got my custom sound chip ordered.

    Sounds as follows...
    1 - Minigun winding up and running
    2 - Minigun firing normal
    3 - Minigun firing crits
    4 - Minigun firing crits with 2 bits of Heavy dialogue mixed in (taunts)
    5 - Minigun running
    6 - Minigun winding down
    7 - TF2 theme
    8 - Announcer stating mission will begin in 10 seconds, then counting down 5, 4, 3, 2, 1, then siren for round start
    9 - Announcer congratulating winning team (your team won with applause and so on)
    10 - Heavy OM-NOM'ing ... followed by "That was delicious!"

    I can't wait to get this thing completed with full lights and sound!

    (Sound 8 should be fun to play when I get into an elevator or when I'm waiting with a crowd at closed doors to enter a panel or room).
  19. RPF Premium Member Bayouwolf's Avatar
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    Long Beach, CA
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    Feb 17, 2014, 8:00 PM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #19

    This is such a fun build!
    I mean....Mini guns are cool and all, but a TF2 mini gun? That's cool on a level below freezing...

    Sub'ed for sure!
  20. TazMan2000's Avatar
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    Nov 2009
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    Sherwood Park, Alberta, Canada
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    Feb 17, 2014, 10:05 PM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #20

    That was printed on an original maker bot? Wow. I'm impressed.

    TazMan2000
  21. drjag's Avatar
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    Kent, UK
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    Feb 21, 2014, 11:12 AM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #21

    Wow, it spins so effortlessly! Have you tried it horizontally aswell? It's just a thought but because the shaft is quite long, it's weight may have an affect at the front where the shaft might bend down a little, affecting the rotation. Just curious about that.
  22. coryalex's Avatar
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    Feb 21, 2014, 11:43 AM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #22

    drjag said: View Post
    Have you tried it horizontally aswell?
    Yes, I've tried it horizontally, and it spins very well. There is a little more drag, but not much. I just didn't have a jig or enough hands to hold it and spin it for video.

    This weekend, I plan on assembling (and painting) the barrel assembly... with luck, I'll get to test rotation with the actual motor AND wire up the lights. We'll see how much I get done. I'll be sure to post videos and pics of anything interesting.
  23. coryalex's Avatar
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    Feb 24, 2014, 10:01 AM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #23

    Update for what I got done this weekend.


    1) Modeled and started printing bullet parts for my bandolier.


    2) Wired up the electrical for the lights (static portion only... barrels not wired yet)


    3) First paint applied to barrel components. Final paint will be applied now that the barrel assembly is done (minus electrical... paint first, electrical after).


    4) Rotating barrel assembly complete (minus paint and barrel wiring).


    5) Barrel spin test complete... spins smoothly with perfect balance... should be able to achieve quite a reasonable RPM with this build, and I've printed 2 motor pulleys... one will allow barrel to run at full 300 RPM, the other turns it down to only ~150 RPM... but I think 300 is well within the do-able range.




    Here are some photos!


    Modeled bullet parts (I figured since the Heavy's chocolate bar has TF2 logos, then maybe his bullets should, too)




    Printed bullet parts



    Soldered ends for energizing barrels as they pass by




    Here's how the spacing of the barrel internals will go



    O-rings will serve as my drive belts




    First step of assembly was to ensure straightness of the first stage retainer



    Here's a photo of the FINAL dry fit (just need to add glue, but fit was SO tight, I don't have to worry much about it moving)





    And here's a new YouTube video of the turning of the final assembly... even horizontal.
    She spins very smooth with great balance.


    https://www.youtube.com/watch?v=k7HZfK_euBI




    Next steps will include:
    - painting of barrel assembly
    - wiring of LED pods in each barrel along with connectors at back end of each (I'll post a video when I get this tested and working)
    - begin mockup of ammo drum and frame for holding her all together
  24. RPF Premium Member laellee's Avatar
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    Feb 24, 2014, 10:10 AM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #24

    Nicely done on this, you know how much spinning that barrel horizontally would magnify any problems with things being trued and balanced properly...... You've got it spinning like a machined assembly
  25. coryalex's Avatar
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    Feb 24, 2014, 11:55 AM - Re: Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY) #25

    laellee said: View Post
    ... you know how much spinning that barrel horizontally would magnify any problems with things being trued and balanced properly......
    Funny you should say that... my 9-5 job is running a company which manufactures rotating equipment.

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