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Archive&Future

Sr Member
RPF PREMIUM MEMBER
My friend Jem (Pippin96) and I have decided to build up a pair of Denix blasters, so we're adding an umpteenth Denix thread to the RPF here- I doubt we'll add anything that hasn't been done before, but it's always enjoyable to share a project.

I started with the disassembly, which necessitated drilling out the firing pin.
I filed the end of the breechblock flat and then drilled out the pin using a center drill and 6mm endmill with the receiver assembly mounted in my mill.

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I then roughly cut the barrel off before squaring the receiver up.

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Using some Dykem marking fluid, a center finder and a scribe, I prepared the receiver to be bored out. Once the center was drilled and aligned, I rotated the receiver vertically so that I could drill out the bore using a 12mm drill. To keep everything aligned properly I used a 2D level and setup blocks (not pictured)

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To add some authenticity I decided to add a 'serial number' to the receiver; the lettering is oversized compared to real C96s, but it's a detail I'm happy with nonetheless.

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My next step will be to cut out new grips from a block of black American walnut.

Thanks for looking, and stay tuned!
 

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ID10T

Sr Member
Good milling technique!

It should be a smooth build.

I started printing parts for one myself. So far happy with the results (dovetail for the scope is so tight I need to sand some relief into it!)
 

Archive&Future

Sr Member
RPF PREMIUM MEMBER
This is great! Are you guys to thread the bull barrel on, like the Todd's Costumes blaster?
No, I'm planning to have mine slide into place and then secure it with a pin or grub screw, since I don't want any error in alignment that might happen with a threaded barrel.

Today we continued with the two Denix builds. Jem had already made headway with reshaping his, so I followed suit on mine. To add a certain level of realism, we chose to mill out the recesses in a purposefully rough manner using slow speeds, fast feeds, and an endmill with more flutes than is suitable for soft metal like this.

We also milled out the bottom of the gun, as this will have a separate plate just like the real thing; I've already ground a piece of HSS into a T-slot cutter, and we'll use steel for Jem's magazine cap and brass for mine. I also began machining a prototype bull barrel from low carbon steel, but I ran into concentricity issues with my smaller 3 jaw chuck, and then discovered that the 12mm bore I made in the receiver was also tapered. I fixed the issue with a 1/2" reamer, but the bull barrel mounting peg is now undersized, so that will need to be remade.

Not pictured are our successful experiments with Birchwood Casey gun bluing- I found the best combination is 50/50 brass black and steel blue.

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