bigbisont
Well-Known Member
I know there are already a hundred "boo" builds here, but I wanted to document this one as I attacked it a way I hadn't seen done before (at least not noticed any documented builds this way).
Tools used: Common rotary tool, an regular 4.5" angle grinder (w/stand to hold it still so you could use both hands on piece), and a drill press
I started, as most do, with a Denix LeMat.
Converting it from the army/navy version to the cavalry versions was...fun. Lots of fun!...
Anyways, first things first, you need to start chopping.
Ground off the standard loop at the bottom of the handle, but decided to keep part of the 'shotgun' underside. I figured it would be a strong spot to anchor the pending 'greeblies'. I can't say I recommend this way as tons of grinding it thinner was required, but it did work.
Cut off the standard 'nub' and found a different more accurate steel nub off a "display hook" (like stores use). Drilled and tapped the sides then JB welded together. That thing is going nowhere.
For the main underside greebly I got some 1" OD aluminum tube (3/4" ID). I cut multiples and built 3 of them because this was hard as hell and I knew I would butcher at least 1. I built 3 so I could take the best one and use it.
There were actually 4, but the test piece got all kinds of mangled.
Here is where grinding the bottom part of the shotgun that I left in tact came into play. I had to get it down to 3/4" so my 1" OD aluminum tube could slide over it, and that was not as easy as I had hoped. But I did eventually make it fit.
It was damn near impossible to find an appropriately sized front "cap" to the greebly body. I searched everywhere for a common item I could convert. I ended up going with a stainless measuring spoon. $3 from walmart and I just need the "TBsp" size one. I chopped it up and grinded it down to fit.
Not a bad start!
At this point I started feeling like I could actually make this thing work.
I drilled out the center of the curve and 'steel-sticked' a heck bolt in there. It doesn't actually turn but it looks the part (seen later)
For the top rail, I cut out a couple slits of 1/4" aluminum (again, a 'couple' because I was sure I would hack up at least one, which I did.)
I used a 1/4" drill bit to remove the bulk of the material for the 'notches', then used an old fashioned hand file to square up the edges. It was miserable, but it worked.
Then a little tap and thread action followed by grinding off the tops of the screws so they were flush. (I did counter sink them to the best of my ability, but they still did stick out the top a bit)
really feeling it now!
Tools used: Common rotary tool, an regular 4.5" angle grinder (w/stand to hold it still so you could use both hands on piece), and a drill press
I started, as most do, with a Denix LeMat.
Converting it from the army/navy version to the cavalry versions was...fun. Lots of fun!...
Anyways, first things first, you need to start chopping.
Ground off the standard loop at the bottom of the handle, but decided to keep part of the 'shotgun' underside. I figured it would be a strong spot to anchor the pending 'greeblies'. I can't say I recommend this way as tons of grinding it thinner was required, but it did work.
Cut off the standard 'nub' and found a different more accurate steel nub off a "display hook" (like stores use). Drilled and tapped the sides then JB welded together. That thing is going nowhere.
For the main underside greebly I got some 1" OD aluminum tube (3/4" ID). I cut multiples and built 3 of them because this was hard as hell and I knew I would butcher at least 1. I built 3 so I could take the best one and use it.
There were actually 4, but the test piece got all kinds of mangled.
Here is where grinding the bottom part of the shotgun that I left in tact came into play. I had to get it down to 3/4" so my 1" OD aluminum tube could slide over it, and that was not as easy as I had hoped. But I did eventually make it fit.
It was damn near impossible to find an appropriately sized front "cap" to the greebly body. I searched everywhere for a common item I could convert. I ended up going with a stainless measuring spoon. $3 from walmart and I just need the "TBsp" size one. I chopped it up and grinded it down to fit.
Not a bad start!
At this point I started feeling like I could actually make this thing work.
I drilled out the center of the curve and 'steel-sticked' a heck bolt in there. It doesn't actually turn but it looks the part (seen later)
For the top rail, I cut out a couple slits of 1/4" aluminum (again, a 'couple' because I was sure I would hack up at least one, which I did.)
I used a 1/4" drill bit to remove the bulk of the material for the 'notches', then used an old fashioned hand file to square up the edges. It was miserable, but it worked.
Then a little tap and thread action followed by grinding off the tops of the screws so they were flush. (I did counter sink them to the best of my ability, but they still did stick out the top a bit)
really feeling it now!
