Armorer Works DL-44

Robiwon

Master Member
Gone but not forgotten.
So, I decided to go with the AW DL-44 commonly found at shops like Evike airsoft here in the states. This is my first blaster and my first attempt at weathering such an item. I'll be making a few mods to the gun. Now, I'm no expert on blasters so I'm not going for screen accuracy. I'm just trying to learn how to do this as I go along. From what I have read it also is not screen accurate in details to the ANH and is closer to the TFA version.....OK....
I do know that the front grill is too short and the brass knob on the scope too tall. I am having a Shapeways designer design a new, direct replacement grill that will snap in place just like the stock part. It will be longer and will be available in ANH and TFA versions.
So, the first mod I did was add a groove in the knob. This helps reduce the visual height of the knob. I chucked it in my Dremel and with a steady hand, ran a triangular needle file to it. Turned out pretty good.
Next, I started weathering. I used a variety of sanding pads and sticks to knock down the shine, expose the metal on corners and blend it all together. For my first attempt it came out pretty good I think.
 

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Tuff stuff! I soaked my barrel in Easy Off oven cleaner overnight and the it came out untouched! So, I spent about half an hour with a sanding stick and sanding pads and came up with this!

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After a few more minutes, I had this.

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And then testing the barrel.

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Got my Aluminum Black in the mail today. I'll be dipping the barrel tonight. Also got my piston sights from Todd's Costumes. What a great day to be working on a Blaster!
 
Pictures tomorrow, but the Aluminum Black worked great. As an added bonus, it also worked on the brass scope rings!
 
Birchwood Casey Aluminum Black worked great. Flash hider and scope rings.
 

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While I wait for the custom AW grill to be made by Sly Tools, I picked up one of his HFC TFA grills to see how close it matches the WA frame. Pretty close. The profile to frame is really close but a bit short on the side. You can see part of the slots for the stock piece to snap into. Thes will be corrected in the new AW grill.
 

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Sanded the flash hider with super fine steel wool. Did another dip in Aluminum Black, run under cold water, dry off. Repeat. After each dip and sanding, the base metal gets darker and darker. I think I'm happy with this shade of dark aluminum.
Temporary TFA grill painted and expoxied in place. I filed a notch on the bottom so I can easily pop it off when the new grill is ready.

Oh, and feel free to comment....
 

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Just a quick update. Sly Tools has received my AW grill. Over the next few days he will be working on the new 3D printed version. A section will be made available for me to check the fit and snap on feature. If no changes are needed then the full version will be tooled up.
 
The new ANH/TFA grill is getting close. He sent me some pics of the prototype. Looks great. Keep you posted...
 
Prototype test part ordered. When it arrives next week I'll check the fit and size. If it's good the final part should follow shortly thereafter.
 
I replaced the cap head screw with a 10-32x1/4 set screw. Perfect fit. Not screen accuate, but if you like a smoother appearance...
I'll put the cap head screw back on though.

Should have the blank test grill by weeks end. While it has no details it will verifiy the fit and inner profile. As soon as it comes I'll post pics of the fit and function of it.
 

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The final production piece arrived this morning from Shapeways! But of course I'm at work. As soon as I get home I'll try this new AW grill on for size and snap some pictures!

After I get the grill on, I'll need to figure what to do about the "Mystery Disk"!
 
Well, what do you think? More pics coming after painting and weathering.
 

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New grill painted and installed. So much better than the stock part!

Here is how I did my mystery disk. Made a paper template and marked the center. I drilled a new hole after filling the old one with JB Weld. I then made a new disk out of aluminum foil.This was brushed with Kristal Klear and put in place. It was then burnished down. Once the glue sets I'll buff it a bit and add a little weathering.
 

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Looks great! I am so tempted to get one of these to complete my OT Han Solo blaster collection...

Plus I have a rabbit problem in my backyard, and this would be a fun way of taking care of that.

Sean
 
After staring at my "disk" for a day, I'm not real enthused with it. Especially after finding an old bag of computer parts!
 

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