Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY)

coryalex · Mar 5, 2014

Gombabomb said:
... Is this going to be a go-to kind of costume for you for a while?

We'll see. I went through quite an effort to build Vera for my Jayne getup last year at Phoenix Con, but I only wore it once after that (to Tucson Con for one day). Now, my Vera(s) hang on the wall (one at home and one at the office). And I've also built a complete full-scale Ecto Containment Unit along with my complete GB getup for use with my charity work (AZGB).
I just tend to latch onto a project and go full-bore until it's really sweet. I don't know if I'll use the Heavy getup after Phoenix Con or not. I really like building things, and with my limited time, I just build one thing at a time until it's as done as I want it (usually too many hours and too much time and money).

In the end, I think it will really depend on the reception I get and how much fun I have in it. If I have fun running around blasting with the minigun while shouting in a Russian accent and it results in lots of smiles, then I'll probably use it more.

TheShinyOne · Mar 5, 2014

Very very cool. Although I have no idea how to make it any other way than you did, don't you think, now you've seen the strobing effect, that it would have been easier to go with one light and a plate with holes that rotate in front of the light? But maybe that would have meant a very bright light needed at the stationary part, I dont know.

Your way is certainly cooler!

coryalex · Mar 5, 2014

TheShinyOne said:
... don't you think ... that it would have been easier to go with one light and a plate with holes that rotate in front of the light?...

Possibly, but I really, really wanted each barrel to fire, full light. I didn't think there was any other way to get full intensity, instant on and off of each barrel than to do it with LEDs and a dynamic contact. I was afraid any other way would lead to a fast fade in/out or lower intensity.

In the planning stages, I devised a compressed gas venting system centrally located in the barrel assembly to vent gas with the strobing lights as the barrel assembly spun to emulate more realistic muzzle flash... but I decided not to get that elaborate on this build.

3oin · Mar 6, 2014

This could be amazing ! can't wait to see the final reveal

*gets popcorn*

3oin

Chaank · Mar 6, 2014

That's a million kinds of awesome!

Duncanator · Mar 6, 2014

I love the Heavy in TF2! Your gun looks great!
I'm not surprised that the tiny motor you had wasn't able to spin the barrel assembly, and you are wise to go with bigger motors. More Torque!
I suspect the little one would have burned out from the strain pretty quickly considering the mass it had to overcome when starting up.

Can't wait to see it done!

coryalex · Mar 6, 2014

Duncanator said:
I love the Heavy in TF2! Your gun looks great!
... I suspect the little one would have burned out from the strain pretty quickly considering the mass it had to overcome when starting up. ...

Yeah... my new motors showed up... they're substantially bigger AND I'm going to see how one does, but I'm probably going to design a rig to run both motors in tandem to share the load... I want to leave nothing to chance.

coryalex · Mar 7, 2014

UPDATE!

One of my best friends bought me the Team Fortress 2 Heavy doll! (action figure, whatever)
This should help provide me even better reference with the tiny gun it came with.

Since I've decided to run TWO motors to drive the barrel, I needed to devise a mount that not only holds 2 motors, but also holds 2 tensioning pulleys to keep the belts aligned with the slot in the barrel assembly.
Here's the bracket

The bracket will hold two 300 RPM motors, but I've also bumped up the motor pulley size to increase the barrel speed just a bit.

Here are the tension pulleys (two of them riding on tiny ball bearings will guide the belts between the drivers and the barrel assembly pulley.

Also, here's a demo of the sound kit, if anyone even cares.

Gixxerfool · Mar 7, 2014

What is the spec on the speaker if you don't mind me asking?

coryalex · Mar 9, 2014

Gixxerfool said:
What is the spec on the speaker if you don't mind me asking?

Speaker is rated 20 watt, 8 ohm.

Amp is 7 watt.

I can't wait to hook the amp up with the speaker mounted. I've got a secret surprise on where/how I'm going to mount the speaker... I'm hoping it will serve to let out a good amount of sound while being pretty camouflaged.

Gixxerfool · Mar 9, 2014

coryalex said:
Speaker is rated 20 watt, 8 ohm.

Amp is 7 watt.

I can't wait to hook the amp up with the speaker mounted. I've got a secret surprise on where/how I'm going to mount the speaker... I'm hoping it will serve to let out a good amount of sound while being pretty camouflaged.

Where did you find that speaker?

coryalex · Mar 9, 2014

Digikey, I think. I can probably get a part number, if you want.

Gixxerfool · Mar 9, 2014

coryalex said:
Digikey, I think. I can probably get a part number, if you want.

Thats ok. Thanks. I'm still trying to figure out size for mine. I have a 3 watt amp and am just looking at my options. I'll check them out. Thanks!

coryalex · Mar 10, 2014

UPDATE

Started drilling the barrel assembly for mounting to the handle and ammo can.

With some adjustments to the front bearing holder to make it clear the carriage bolt heads.

Prepared the front of the ammo can.

Started finishing up the handle (3/4" PVC with 1" PVC "sleeves" to keep OD nominal).

Same trick with the frame.

Motor bracket is coming along nicely.

I'm going to mount a small project box on the rear handle with all the switches, so I can operate everything with my right hand while holding the prop.

If you want the full effect of what I got done... watch the video here!

takufuji · Mar 10, 2014

Great build.

coryalex · Mar 12, 2014

UPDATE!

My twin motor rig is complete!

Also, I'm getting close to painting and assembling the ammo can and thought I'd share my method of mounting the speaker in the front of the can in a way that hides it while letting the sound out.

I'm going to hide the speaker behind perforated steel sheet... and I'll mount the ammo can nipple to the sheet with a single bolt from behind. It will provide a nice dark void around the nipple where the speaker can breathe.

Can't wait to get back to work!

metal wood · Mar 12, 2014

love your motor rig, very simple and elegant

coryalex · Mar 17, 2014

UPDATE!

Speaker installed in ammo can (7-up cooler)

Aluminum flashing installed with Shoe Goo on end of cooler... to be Bondo'd and blended into cooler structure for clean lines after flashing is wrapped around the cooler also (need to make iconic riveted flap/seam on side of can)

Handle and Frame will be made from 3/4" PVC sleeved in 1" PVC... then Bondo'd to make the structure a fairly uniform size

Assembly, so far... looking good.

Bullets for bandolier/ammo belt part of my costume

"Wingnut" parts for handle assembly (one per side of bent aluminum plate)

Oh, and for fun, I made these nametags for anyone teaming up with me at Phoenix Con in a TF2 crew

That's it, for now.

PyroDenny · Mar 17, 2014

dang this is killer cannot wait to see it complete!

drjag · Mar 18, 2014

Wow, this build is going together so smoothly!

Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY)

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