Howdy folks. I thought I'd post a thread about a project I've been working on for a few months, one which has been done to death but still gets me pumped every time I see one. I'm building a Han Solo DL-44 (hero version) from ANH, using a Denix Mauser base (with wood grips), some excellent parts from Todd's costumes, and a Hensoldt replica scratchbuilt/converted from a cheapo scope. I've been working on this for a while so this is not exactly in chronological order.
I actually started on the scope first. After scouring the web and eBay for something affordable that resembles Han's scope I pretty much gave up and am building it from scratch, with a bell scavenged from a pretty cheap scope I picked up on eBay. Originally I sawed off one of the bells, planning on using what was left along with a scratch built mount, but the innards (don't know the correct term) were right up against the remaining tube and I couldn't figure out how to remove them. I gradually decided I needed an all metal mount anyway so decided to use a 7/8" aluminum tube so I could use Todd's scope mount. I picked up the tube on Amazon for a couple bucks and used the removable rear bell from the other scope. It was a 1" tube so I had to figure out how to reduce it to meet the 7/8" aluminum. I cut short slice from the 1" tube and used it as a spacer, filling the steps with Bondo and sanding smooth.
Original scope bell and spacer
I'm pretty pleased, it matches the shape of the Hensoldt well though the taper where it meets the tube isn't 100% perfect. Unfortunately since the filler is Bondo I won't be able to blue the scope easily, so I guess it will be paint. I also used a tubing cutter to scribe a line near the tip to represent the brass parts. I haven't sorted out a front lense yet, if anyone knows where to get a cheap lense I'm open to ideas!
As likely everyone knows the finish on the Denix is pretty nasty, far from smooth with poor paint application and some metal pitting. I did the standard sand sand sand working up from 250 to 500 grit and have gotten it pretty smooth. Some flat surfaces and angles (base of the barrel etc) were worked with files to get clean angles. This was a lot of work but I find it very satisfying and meditative, great while binge watching Netflix.
Before sanding
After
There are a bunch of details that need fixing, once again nothing too original. I repaired the knurl on the hammer, bolt, and sight slider (should I try to rework this to a diamond knurl?). I also re-shaped the top of the hammer with files and a sanding drum/dremel. I wanted to remove the raised bit on the left side but coudldn't think of a way to re-scribe the circles so left it as is. A bit of widening between the trigger guard and handle, and reshaped the blocky trigger. Removed all nasty seams. Finally I removed as much of the V shaped bit at the front of the sight as I could without exposing the hole, and reshaped the front a bit to more closely resemble a real Mauser.
Original trigger
Refined trigger
The Denix is also missing the magazine cover detail. I scribed this in and drilled a countersink for the button. Scribing this stuff is a bitch! I started with a very sharp scribing point and enlarged the lines with my trusty Tamiya scriber. The rear end of the upper is missing a bunch of detail where the real gun would come apart. I wasn't brave enough to do what Lukesfather did on this amazing build, but instead scribed a simplified version of the parting lines. Did I mention scribing pot metal sucks? I have 1 nasty miss that was too deep to remove but I think it came out ok.
Moving on, I was ready to start mating the Denix with Todd's flash hider/bull barrel. Hacked off the Denix barrel with a hack saw and miter box, thankfully it came out pretty straight and a little filing cleaned it up. I recently got a cheap drill press from Harbor Freight for this project, and drilled out the hole for the bull barrel.
Here's a quick dry-fit to see how it's coming along. That's a knurled nut stuck to the scope with sticky tac, more on that later.
That's all the pictures I have cleaned up so far, I'll post more soon. Comments and suggestions are welcome, the more I work on it the more accurate I end up needing it to be, this damn thing is a blast, and addictive!
I actually started on the scope first. After scouring the web and eBay for something affordable that resembles Han's scope I pretty much gave up and am building it from scratch, with a bell scavenged from a pretty cheap scope I picked up on eBay. Originally I sawed off one of the bells, planning on using what was left along with a scratch built mount, but the innards (don't know the correct term) were right up against the remaining tube and I couldn't figure out how to remove them. I gradually decided I needed an all metal mount anyway so decided to use a 7/8" aluminum tube so I could use Todd's scope mount. I picked up the tube on Amazon for a couple bucks and used the removable rear bell from the other scope. It was a 1" tube so I had to figure out how to reduce it to meet the 7/8" aluminum. I cut short slice from the 1" tube and used it as a spacer, filling the steps with Bondo and sanding smooth.
Original scope bell and spacer
I'm pretty pleased, it matches the shape of the Hensoldt well though the taper where it meets the tube isn't 100% perfect. Unfortunately since the filler is Bondo I won't be able to blue the scope easily, so I guess it will be paint. I also used a tubing cutter to scribe a line near the tip to represent the brass parts. I haven't sorted out a front lense yet, if anyone knows where to get a cheap lense I'm open to ideas!
As likely everyone knows the finish on the Denix is pretty nasty, far from smooth with poor paint application and some metal pitting. I did the standard sand sand sand working up from 250 to 500 grit and have gotten it pretty smooth. Some flat surfaces and angles (base of the barrel etc) were worked with files to get clean angles. This was a lot of work but I find it very satisfying and meditative, great while binge watching Netflix.
Before sanding
After
There are a bunch of details that need fixing, once again nothing too original. I repaired the knurl on the hammer, bolt, and sight slider (should I try to rework this to a diamond knurl?). I also re-shaped the top of the hammer with files and a sanding drum/dremel. I wanted to remove the raised bit on the left side but coudldn't think of a way to re-scribe the circles so left it as is. A bit of widening between the trigger guard and handle, and reshaped the blocky trigger. Removed all nasty seams. Finally I removed as much of the V shaped bit at the front of the sight as I could without exposing the hole, and reshaped the front a bit to more closely resemble a real Mauser.
Original trigger
Refined trigger
The Denix is also missing the magazine cover detail. I scribed this in and drilled a countersink for the button. Scribing this stuff is a bitch! I started with a very sharp scribing point and enlarged the lines with my trusty Tamiya scriber. The rear end of the upper is missing a bunch of detail where the real gun would come apart. I wasn't brave enough to do what Lukesfather did on this amazing build, but instead scribed a simplified version of the parting lines. Did I mention scribing pot metal sucks? I have 1 nasty miss that was too deep to remove but I think it came out ok.
Moving on, I was ready to start mating the Denix with Todd's flash hider/bull barrel. Hacked off the Denix barrel with a hack saw and miter box, thankfully it came out pretty straight and a little filing cleaned it up. I recently got a cheap drill press from Harbor Freight for this project, and drilled out the hole for the bull barrel.
Here's a quick dry-fit to see how it's coming along. That's a knurled nut stuck to the scope with sticky tac, more on that later.
That's all the pictures I have cleaned up so far, I'll post more soon. Comments and suggestions are welcome, the more I work on it the more accurate I end up needing it to be, this damn thing is a blast, and addictive!