Kurtyboy's project updates: 24 July - More blasters

kurtyboy · Apr 29, 2016

Project Updates 30 April - Sandtrooper Lewis Gun (Hyperfirm)

Anyway.......

As the old saying goes: "Why finish one project when you can just start another?"

I had a nice hyperfirm Lewis Gun years ago but was forced to sell a lot of stuff. Always wanted another one. Managed to get a very badly ("re" - it seems) cast Lewis Gun. Comes from a badly damaged mold with lots of issues and very bad seams.

After trimming. Actually looks okay.... from a distance!

Some hobby knife and Dremel work.

This damage would just be too difficult to really clean up so I decided to cut inlays to cover it up.

Got some advice from Robstyle to use Super (CA) Glue and activator spray for filling work.

Stay tuned...

Stormy320 · Apr 30, 2016

Re: Project Updates 25 April - MPP, Leia Rubies (there's a good reason), Nostromo bla

Looks good

Lichtbringer · Apr 30, 2016

Re: Project Updates 25 April - MPP, Leia Rubies (there's a good reason), Nostromo bla

Looks like a lot of hard work to get this acceptable. Good luck.

kurtyboy · Apr 30, 2016

Project Updates 30 April - Hyperfirm Sandtrooper Lewis Gun mods.

More work on old Lewis.

I didn't like the solid rear sight so I hollowed it out.

Also plan on adding the threaded rod and if I can find a suitable knurled thumbwheel I will replace the rubber one.

Thumbwheel on real Lewis Gun rear sight.

The cocking handle was obviously filled before casting

Real Lewis Gun cocking lever.

I'm no machinist having only a few hand tools so I made a new one using what materials I had on hand.

Real Lewis Gun cocking lever.

- - - Updated - - -

Thanks Michael. Yeah, rubber is a nightmare to fill and sand/reshape. I should have tried to get a resin casting instead!

Lichtbringer said:
Looks like a lot of hard work to get this acceptable. Good luck.

Lichtbringer · Apr 30, 2016

Re: Project Updates 30 April - Hyperfirm Sandtrooper Lewis Gun mods.

I´m sure you can handle it - i know no other person that can put so much passion and patience on working stuff to get it right like you.

Maybe no fun with it (probably not), but at the end you will get it done.

kurtyboy · Apr 30, 2016

Re: Project Updates 30 April - Hyperfirm Sandtrooper Lewis Gun mods.

The rubber is hard enough to fill and reshape (it's just not possible to get it as clean looking as you would resin), but the foam inside the rubber outer layer is impossible to clean up. So far the only thing to do seems to be to cover it up but that's not always possible.

I'm replacing the destroyed rubber sling rings with metal ones.

Drilling out holes that were filled for casting.

And probably a bad idea but trying to add the missing barrel radiator fins. I had to cut into the foam here and need to dig deeper, but my dremel flexible extension cable snapped.

I will also replace as many rubber screws with real ones as possible. Looking forward to adding the sling (parts are on the way) and adding greeblies. I wish there were better reference photos out there.

kurtyboy · May 1, 2016

Re: Project Updates 30 April - Hyperfirm Sandtrooper Lewis Gun mods.

It was only while studying pictures of real Lewis Guns that I realized the block on the front clamp is supposed to be the front sight. Evidently too complex a shape to cast so they filled it before casting.

Carved the front sight into the rubber with a knife and dremel to round off the grooves.

Real Lewis Gun front sight. Looks like the solid filled barrel also needs a bit more detail added.

thd9791 · May 2, 2016

Re: Project Updates 30 April - Hyperfirm Sandtrooper Lewis Gun mods.

God this must be painstaking, it looks great!

Side question - what's your favorite filler/putty to use?

also, I may have picked up some clear diamond patterned light diffuser sheets, like on your ROTJ rifle scope, how'd you cut circles out of that?

kurtyboy · May 2, 2016

Re: Project Updates 30 April - Hyperfirm Sandtrooper Lewis Gun mods.

I use Upol Quicksand for most filling. Sometimes Milliput if it's a larger area and needs to be sculpted. Neither are any good on rubber though

I cut my scope lenses roughly with a hacksaw (end up with an uneven octagonal shape) then file them down.

thd9791 said:
God this must be painstaking, it looks great!

Side question - what's your favorite filler/putty to use?

also, I may have picked up some clear diamond patterned light diffuser sheets, like on your ROTJ rifle scope, how'd you cut circles out of that?

kurtyboy · May 2, 2016

Re: Project Updates 30 April - Hyperfirm Sandtrooper Lewis Gun mods.

About the best I can do with the highly inaccurate barrel shroud on these castings. The taper was obviously added since the shroud would be too thin to cast in rubber.

the radiator fins have been simulated with a decal.

If I can find a metal or plastic tube the correct diameter it might be possible to gouge out the thick tapered wall and insert that for strength.

Sluis Van Shipyards · May 2, 2016

Re: Project Updates 30 April - Hyperfirm Sandtrooper Lewis Gun mods.

That looks great so far! That's one of my favorite blasters I'll have to get eventually.

trooper · May 2, 2016

Re: Project Updates 30 April - Hyperfirm Sandtrooper Lewis Gun mods.

WOOOOW!!!, absolutely amazing !!

kurtyboy · May 5, 2016

Project Updates 6 May - MPP shroud wrinkle paint take two

Another attempt with a different brand of winkle paint. Definitely wrinkled this time but not quite right.

After curing in the oven and lightly sanding with 800 grit to remove the shine. DIY on the left, original on the right.

Wild variations in the wrinkle paint even on original parts.

OdiWan72 · May 9, 2016

Re: Project Updates 6 May - MPP wrinkle paint

Looking great buddy.
The almost smooth shroud on the third MPP seems to be a close match to the hero ESB sabers emitter tip. You should consider switching these :thumbsup

kurtyboy · May 12, 2016

Project updates 12 May - Hyperfirm Lewis Gun more mods.

Thanks Markus, I will swap the MPP shrouds over.

Some more detail work on the Lewis Gun. All the screws and hardware replaced with real ones and sling tested.

And some progress with the Nostromo pistol. Markus is guiding me with the paintjob.

Some reshaping to the receiver cover here.

and here.

Ready for paint after three weeks of obsessive cleanup. It's perfect now!

Gunmetal base coat down.

Lichtbringer · May 12, 2016

Re: Project updates 12 May - Hyperfirm Lewis Gun more mods.

The Lewis is getting nicer. :thumbsup

As i said above - all Marcus needs is invest enough time to work on something, and he gets everything to shine.

RetiredClone · May 12, 2016

Re: Project updates 12 May - Hyperfirm Lewis Gun more mods.

Beautiful work! Nice use of real screws, they add a really good touch.

Stormy320 · May 12, 2016

Re: Project updates 12 May - Hyperfirm Lewis Gun more mods.

That Lewis looks bad *****

OdiWan72 · May 12, 2016

Re: Project updates 12 May - Hyperfirm Lewis Gun more mods.

Great progress!

BTW...I just checked the buttplate on my Lewis cast and it doesn´t have any markings on it. So swapping it out to a metal plate should be a big improvement to the overall look

What is your approach for the ribbed tubing abround the barrel housing? Found anything remotely close yet?

kurtyboy · Jun 11, 2016

Project updates 11 June - Leia blasters and Hyperfirm Lewis Gun more mods.

Thank you guys. I did some more work on the Lewis Gun. Really gouged out a lot from the back of the barrel shroud so that a 3D printed piece of the radiator fins can be inserted. As well as 20mm deep I also cut out a chunk 10mm down so the added radiator fins will be behind the ledge.

Although I can't make out any din plug on the original prop, I like the look of this Merr Sonn style scope.

Leia blaster madness. From top to bottom: Resin Odiwan72 kit cast from real Margolin, real deactivated Margolin with vintage parts, lightweight Rubies conversion for my lifesize Leia display, resin cast from original RotJ. I may get another Odiwan72 kit and make a more idealized RotJ version.

Coiled cable from vintage headphones, machined extension and compensator from Scottjua.

Kurtyboy's project updates: 24 July - More blasters

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