Budget Boba Fett ESB sidearm scratch build

mykindofscum

Sr Member
RPF PREMIUM MEMBER
Here is my budget Boba Fett ESB sidearm build. I'm posting it simultaneously on TheDentedHelmet.com and TheRPF.com, so apologies if anyone has to suffer through it twice.

So earlier this summer, I had been geeking out pretty hard on Boba Fett's sidearm blaster, as barely seen in The Empire Strikes Back, as well as some sweet-looking fanmade replicas on TDH that are based on found items. I'd really like to buy either one of those, but neither version is currently in my budget.

One day, I was at a thrift store, and saw a watergun with handgrip kind of sort of somewhat similar to the one on the sidearm/found item. I got the wacky idea that it would be fun to try and build a budget homemade Boba Fett ESB sidearm from the watergun. So, I invested the 99 cents into the gun.
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I cannot measure, draw, cut, sand, or paint in a straight line to save my life. But I try a lot. I absolutely know that if I touch a project, I am going to screw it up by over-doing one of the above actions, or something else. That's just how it goes. Despite knowing that each time, I begin each new project certain that it will be the first one that goes right, the gates of Heaven will open with trumpets blaring and The Knowledge of Building will be given to me with the touch of a heavenly finger on my forehead or something. It's crazy. ("Oh, I'll just bend this hard-to-find key component a little and it will fit perfectly..." *breaks* "Noooooo! Not again!!!")

So, with my new 99-cent Goodwill watergun, I decided to set the rules of a build challenge for myself. Basically: In addition to the watergun, to use only materials that I already had, don't buy anything else. I knew I had a fair amount of odds and ends from various other projects that could work for certain parts, and maybe I could learn/figure the rest out along the way? I printed a small couple of reference photos from TDH threads and reference library, eBay listings, and Google - all either real found items or fanmade replicas. I believe the fanmade ones were MojoFett and Spideyfett's (man, both of theirs were sweeeet!!).

Okay, let's get started. First step, cut the grip off of watergun. I also trimmed the base of the handgrip. Still not sure as I post this how I am going to finalize that part.
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Next, cut a piece of PVC pipe for the back half
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Then cut out the open area. I didn't know how to measure this, so I winged it and made the cuts on a bandsaw by eyeballing it. I think I nicked a corner, which was so disappointing, but will fit in with that Star Wars "used universe" beat-up weathering I love so much.
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Here's the direction it's headed, slide a smaller piece of PVC pipe cut to guessed barrel length inside the larger-diameter cutout piece.
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And placed inside to see how it will look. Because things that look like guns are cool. Fezzes are cool, too.
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Thought the barrel was a little bit too long, so cut it down just a bit
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Needed a thick round end cap for the butt end of the cut-out piece. Stood the PVC cut-out piece on a old thick plastic tray I'd bought at the thrift store a long time ago as a flat surface to make molds on or something. Traced a circle around the cut-out piece.
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I cut out a piece much larger and rougher than what I traced around the PVC. I think it was almost square, actually. Then I just shaped it by holding it and running it over the belt sander until I got a circle shape along the traced marker line.
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Repeated the process for the front end of the smaller PVC piece, which will make up the main barrel.
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Glued them on with E6000. The dark dust is from sanding the cut piece from the tray down to a circle.
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Another test fit just for fun
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Hmmm, what did I have around that could make the smaller tip which comes out of the main barrel? Decided to nip a piece of an aluminum tube that was destined for a Tusken Rifle, along with a smaller dowel rod.
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Here I'm just holding the pieces stacked on top of each other, to see what a profile view would look like. The little green piece is cut from the scope thingy that I cut off of the watergun. I got a big kick out of being able to use another piece of the 99-cent watergun in the build.
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more to come, just breaking up the posts...
 
Last edited:
Re: Budget ESB sidearm scratch build

...and, we're back.

Drilled a hole in the primary barrel's cap, then widened the hole
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The dowel will insert through the green ring (now drilled out as well), and into the barrel.
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Cut a piece off of the aluminum tube
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Here we go
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and sanded here and there for a fit and glued together
708b8de9.jpg


At this point, my build was disrupted when a Mynock flew into my garage. Well, at least it was as big as one, and it flew about as straight as a drunken one-eyed kamikaze pilot on fire. If my neighbors tell you they heard crashes and girlish yelps coming from my garage that night, pay no mind to their outlandish, fanciful stories.
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Eventually, only one of us was left standing, and it wasn't the Mynock. On with the build.

I drilled holes through the top of the back end of the inner barrel (smaller PVC piece), and the dowel rod, for holding the dowel rod in place at the back end.
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On the front end of the dowel, drilled a few holes in more or less a line
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...

...until I could work a file in there and smooth it out
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Put all the barrel assembly together
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Now needed to add the final barrel tip pieces. I used a hairspray cap (the clear piece), and a drink cap (a Diet Mountain Dew, ughh!. I had tried for a while to switch to the unleaded fuel, didn't work out.) Drilled hole in the bottle cap, widened it, slide the hairspray cap through it.
e95c96b4.jpg


Finally got around to actually gluing the watergun handgrip to the larger PVC piece
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Here's how it looks as of this post, hope to get to it some more this weekend.
5db76324.jpg
 
Re: Budget ESB sidearm scratch build

hey did you ever end up finishing this build? looks like it was going great

...and, we're back.

Drilled a hole in the primary barrel's cap, then widened the hole
http://i586.photobucket.com/albums/...ums/TDH/Budget ESB sidearm build/a7b277cb.jpg

The dowel will insert through the green ring (now drilled out as well), and into the barrel.
http://i586.photobucket.com/albums/...ums/TDH/Budget ESB sidearm build/f03424a0.jpg

Cut a piece off of the aluminum tube
http://i586.photobucket.com/albums/...ums/TDH/Budget ESB sidearm build/7b10701c.jpg

Here we go
http://i586.photobucket.com/albums/...ums/TDH/Budget ESB sidearm build/53233ca0.jpg

and sanded here and there for a fit and glued together
http://i586.photobucket.com/albums/...ums/TDH/Budget ESB sidearm build/708b8de9.jpg

At this point, my build was disrupted when a Mynock flew into my garage. Well, at least it was as big as one, and it flew about as straight as a drunken one-eyed kamikaze pilot on fire. If my neighbors tell you they heard crashes and girlish yelps coming from my garage that night, pay no mind to their outlandish, fanciful stories.
http://i586.photobucket.com/albums/...ums/TDH/Budget ESB sidearm build/0cefb925.jpg

Eventually, only one of us was left standing, and it wasn't the Mynock. On with the build.

I drilled holes through the top of the back end of the inner barrel (smaller PVC piece), and the dowel rod, for holding the dowel rod in place at the back end.
http://i586.photobucket.com/albums/...ums/TDH/Budget ESB sidearm build/8cee6fc2.jpg

On the front end of the dowel, drilled a few holes in more or less a line
http://i586.photobucket.com/albums/...ums/TDH/Budget ESB sidearm build/d8ec9e6f.jpg...

...until I could work a file in there and smooth it out
http://i586.photobucket.com/albums/...ums/TDH/Budget ESB sidearm build/ef88734b.jpg

Put all the barrel assembly together
http://i586.photobucket.com/albums/...ums/TDH/Budget ESB sidearm build/c5578fde.jpg

Now needed to add the final barrel tip pieces. I used a hairspray cap (the clear piece), and a drink cap (a Diet Mountain Dew, ughh!. I had tried for a while to switch to the unleaded fuel, didn't work out.) Drilled hole in the bottle cap, widened it, slide the hairspray cap through it.
http://i586.photobucket.com/albums/...ums/TDH/Budget ESB sidearm build/e95c96b4.jpg

Finally got around to actually gluing the watergun handgrip to the larger PVC piece
http://i586.photobucket.com/albums/...ums/TDH/Budget ESB sidearm build/300dae84.jpg

Here's how it looks as of this post, hope to get to it some more this weekend.
http://i586.photobucket.com/albums/...ums/TDH/Budget ESB sidearm build/5db76324.jpg
 
Re: Budget ESB sidearm scratch build

hey did you ever end up finishing this build? looks like it was going great

Hey, thanks for the interest and kind comment. I guess I got a little disappointed when I found that the real ones had an oval-shaped barrel (don't know what else should I call it?), and that coupled with pretty much a complete shut-down on all costume builds for the winter. I did get a replica Nemrod holster to go with it, though.

Just picked this blaster and some other projects back up in the last few weeks. I sanded/painted the main barrel, then realized afterwards that I had forgotten to prime it first. Dumb dumb! Boy, was I rusty. No more long breaks like that! I'll give it a quick sanding, then start that part over. And correcting some paint drips I did while painting the holster. Aiming to finish everything by this summer. With pics.
 
Re: Budget ESB sidearm scratch build

super!! best of luck to you! when I finish my travels this is one of the things i hope to build so I cant wait to see how you get on and ill put up a thread when i make mine as well :)

Hey, thanks for the interest and kind comment. I guess I got a little disappointed when I found that the real ones had an oval-shaped barrel (don't know what else should I call it?), and that coupled with pretty much a complete shut-down on all costume builds for the winter. I did get a replica Nemrod holster to go with it, though.

Just picked this blaster and some other projects back up in the last few weeks. I sanded/painted the main barrel, then realized afterwards that I had forgotten to prime it first. Dumb dumb! Boy, was I rusty. No more long breaks like that! I'll give it a quick sanding, then start that part over. And correcting some paint drips I did while painting the holster. Aiming to finish everything by this summer. With pics.
 
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