COMPLETED! Live fire DL 44 Mauser & DEC based

Discussion in 'Star Wars Costumes and Props' started by ktflory, Jun 26, 2015.

  1. ktflory

    ktflory New Member

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    Just another DL44 build. Base is a refurbished C96 with cut and re-welded barrel, sleeved and re-chambered to 9mm by Federal Ordinance. It shot nice 2-3" groups at 25M the other day, I look forward to shooting it with the shortened re-crowned barrel after the conversion. The kit is another DEC kit as received a few days ago. I'd love a real Hensoldt Wetzlar Dialyt if I can find one for under $450.

    I'm satisfied with the kit, but it could be improved. Lots of flashing on the heat sink, took me more than an hour with files to fix it up. I understand the original part was plastic and had seams so I can forgive this. I wish the scope dial was multi-part but I really want a real one so again I give it a pass. The detail on mine was pretty washed out on the sides but good on the top. The scope tube is pretty rough, I have a lot of polishing to do to get it nice and smooth. Also there is no marking on mine, I expected faux trademarks. The scope mount needed about an hour with files to get the fit and finish up to a level acceptable to me. All in all, not bad for the price. I would have shelled out another hundred bucks to improve on the issues mentioned above.

    I am aware my C96 is not completely accurate, I will have a welder take care of most of that while fixing the rust pitting on the grip tang.

    [​IMG]Untitled by Kris Flory, on Flickr

    [​IMG]Untitled by Kris Flory, on Flickr

    [​IMG]Untitled by Kris Flory, on Flickr

    [​IMG]Untitled by Kris Flory, on Flickr
     
    Last edited: Jul 14, 2015
  2. scottjua

    scottjua Master Member RPF PREMIUM MEMBER

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    Re: Build in progress: Live fire DL44 DEC kit

    Good luck! there's so much to getting it to cycle correctly with the extra weight. However, if you're using aluminum bull barrel and flash hider you should have an easier time than with the steel bits.

    You're going to need to figure out a way to get the BB and FH to stay in place during recoil... AND be removable for cleaning, as the sleeve design makes it too tall to just slide off.

    Also, be patient, there are two more super accurate replica hensoldts in the works behind the scenes that you'll be able to choose from soon.
     
    thd9791 and ktflory like this.
  3. LB66679

    LB66679 Well-Known Member RPF PREMIUM MEMBER

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    Re: Build in progress: Live fire DL44 DEC kit

    Just started my path on a non firing DL44 build , looking forward to updates on this !
     
  4. ktflory

    ktflory New Member

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    Re: Build in progress: Live fire DL44 DEC kit

    I'm not concerned about operation, I have messed with light loads in a few pistols before. Springs are easy to tweak and replace. I would like a steel flash hider at some point but if the aluminum holds up to the blast well and gets a nice patina I may leave it. I am worried about the front sight greeblies. I want a permanent way to attach them. Maybe drill a few holes through the push rods and pin them to the T track and bull barrel or something. JB weld ain't gonna cut it for me.

    Cleaning? Who cleans guns these days? I was planning on hiding 3 grub screws under the flash hider and machining a recess into the barrel for them to grab into.

    Thanks for the info on the scopes, I am definitely be interested in getting something nicer. Preferably USEABLE for aiming the thing.

    These are all the "paint only" parts I picked out curing in the oven. The knobs will be shot with flat clear once I rough them up so they look distinct from the rest of the parts. The others are going to be blued or blued then painted for a layered weathered finish.

    [​IMG]Untitled by Kris Flory, on Flickr
     
    Last edited: Jun 26, 2015
  5. scottjua

    scottjua Master Member RPF PREMIUM MEMBER

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    Re: Build in progress: Live fire DL44 DEC kit

    I tried using screws to hold the BB in place, but recoil totally jacked it up. Not enough. Your mileage may vary. Careful as the 100 year old steel will not be as strong. I had to make a new booster threaded to the barrel.

    I've also lost a couple of T track and Push rod sight greeblies. JB weld held for a while, but now I just use small neodymium magnets in the t track base to put the sight greeblie on while displaying, but take it off for range duty. You can sight through the rear sight notch and the top most flash hider knurl just fine.
     
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  6. ktflory

    ktflory New Member

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    Re: Build in progress: Live fire DL44 DEC kit

    I'm actually planning on machining a ring into the barrel to hold the screws similar to how it is done on the airshaft of old GBB airsoft guns. If it can handle that impact and impulse I think a little aluminum on the end should be fine since I'm using at least 3 and friction fitting the sleeve to the barrel at the same time. If I add a steel flash hider I might have issues. All else fails I am leaving an extra 3/4 inch of barrel that will partially protrude into the flash hider as a backup. I can thread that and install a cap that will pull the sleeve against the bulge in the chamber area of the upper receiver.

    Interesting. Magnets, how do they work? I want mine to be fully functional and shoot as displayed because I'm a perfectionist. You had the antenna greeblies angled on yours but I have seen them straight on a few builds. Any hard evidence on which is correct? So far I still plan to attach it using hidden set screws and roll pins.
     
  7. ktflory

    ktflory New Member

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    Re: Build in progress: Live fire DL44 DEC kit

    No machining on the barrel, just cut off. Brazed a brass sleeve to the barrel, X4 set screws through bull barrel to sleeve. Fit is better than expected. Next comes some welding. While I wait on the welder I'll work on the T track and push rod greeblies.

    [​IMG]Untitled by Kris Flory, on Flickr
     
  8. Halliwax

    Halliwax Legendary Member RPF PREMIUM MEMBER

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    Re: Build in progress: Live fire DL44 DEC kit

    is that piece under the air craft pistons the same shape as the t track on the graflex?
     
  9. ktflory

    ktflory New Member

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    Re: Build in progress: Live fire DL44 DEC kit

    I am not en expert but supposedly yes, same cabinet track as used on the E11 and Anakin/Vader sabers. Except this one is cast mystery metal.
     
  10. ktflory

    ktflory New Member

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    Re: Build in progress: Live fire DL44 DEC kit

    Progress interrupted but not stopped.

    [​IMG]Untitled by Kris Flory, on Flickr
     
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  11. ktflory

    ktflory New Member

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    Re: Build in progress: Live fire DL44 DEC kit

    WIP pluck foam case.

    [​IMG]Untitled by Kris Flory, on Flickr
     
  12. ktflory

    ktflory New Member

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    Re: Build in progress: Live fire DL44 DEC kit

    New grips filed down to fit, front sight finished and waiting to be attached.

    [​IMG]Untitled by Kris Flory, on Flickr

    [​IMG]Untitled by Kris Flory, on Flickr
     
  13. ktflory

    ktflory New Member

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    Re: Build in progress: Live fire DL44 DEC kit

    I caught myself losing momentum this weekend due to problems with paint/chemical compatibility on the scope mount so to make use of the energy I still had I "finished" the case. I'm going to make some literature and printouts in Arubesh later, make a in-universe friendly box for the ammo and maybe do some paint work but it is pretty much done. With a little luck I'll have a completed gun to take to the range this weekend.

    [​IMG]Untitled by Kris Flory, on Flickr

    [​IMG]Untitled by Kris Flory, on Flickr
     
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  14. ktflory

    ktflory New Member

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    Re: Build in progress: Live fire DL44 DEC kit

    Getting closer. I was planning on "fixing" the hammer and safety making them close but not exactly like the actual prop, and having a new lanyard lug installed while I had the grip tang welded to fix rust pitting. What do you guys think, is it worth it?

    [​IMG]Untitled by Kris Flory, on Flickr
     
    Last edited: Jul 13, 2015
  15. ktflory

    ktflory New Member

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    Re: Build in progress: Live fire DL44 DEC kit

    I just wanted to positively mention Dave at Dark Energy Creations for responding to my questions about the new detailed DL 44 parts very quickly. Amazing customer service, and I am looking forward to the new bits and pieces!
     
  16. russellsch

    russellsch Sr Member

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    Re: Build in progress: Live fire DL44 DEC kit

    Wow, does this look good! I saw a C96 at a local gun shop the other day, & I wouldn't have the guts to do what you've done. Oh, but I do dream. Hell, I'd be happy with an UNaltered one. I think the design of it is beautiful. But the one I saw was $1,800.
    I will live vicariously through you sir. & I know that whatever range you take it too, it'll be the best gun there.
     
  17. ktflory

    ktflory New Member

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    Re: Build in progress: Live fire DL44 DEC kit

    Mystery disc!

    [​IMG]Untitled by Kris Flory, on Flickr






















    Just kidding, here is the reveal. The vinyl was given to me for free as a "solution". I said thanks but used it as a mask instead. I'll add the dot later. I am 99% convinced the real deal was a ring of glue surrounded by black paint where an Imperial officer's disc fell off.

    [​IMG]Untitled by Kris Flory, on Flickr
     
  18. Panaflex

    Panaflex Sr Member RPF PREMIUM MEMBER

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    Re: Build in progress: Live fire DL44 DEC kit

    Smokin'.
     
  19. ktflory

    ktflory New Member

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    Last edited: Jul 14, 2015
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  20. ktflory

    ktflory New Member

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    The blaster has been done for a bit. I've just been making a few tweaks. I had the epoxy break loose on the heat sink once, and since the outer barrel kept moving I put in additional hardware to lock it down. That mass was enough to interfere with ejection of spent casings so I am experimenting again with lightened hammer springs. The "recoil" spring is a misnomer, it essentially just feeds fresh rounds into the chamber. I think Mauser defines it as the bolt return spring instead.

    [​IMG]Untitled by Kris Flory, on Flickr
     
    Last edited: Dec 21, 2015
  21. scottjua

    scottjua Master Member RPF PREMIUM MEMBER

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    Looks like you're seeing everything I ever had to deal with. Looks like it's already started, but soon your mount upright will bend forward. IF it's the cast kit, which it looks like it is.

    I had to lighten the hammer springs too on the ones I built
     
  22. Badmutha6

    Badmutha6 New Member

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    Following. Looks great!
     
  23. ktflory

    ktflory New Member

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    The scope offset was due to the holes in the aluminum crossbar being off center, It was like that before install so I could choose upward cant or downward. I figured I'd just make a new one at some point to fix it. If the scope mount does bend I'll have to get a steel mount I guess.

    Yep its all cast. I didn't bite fast enough to get any of the steel parts on the last run.
     
    Last edited: Dec 23, 2015
  24. Oletennessean

    Oletennessean New Member

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    im very interested in building a working model of one of these. How does adding all attachments make the weapon not cycle properly?
     
  25. ktflory

    ktflory New Member

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    The action recoils a fraction of an inch rearwards before unlocking the bolt, then the bolt moves backwards and ejects the spent casing. If there is extra mass on the barrel (and there is, I weighed the section of cut barrel and the parts) it weakens the recoil impulse and delays locking, leaving less energy to properly cycle the bolt. So I used a weaker hammer spring coupled with a stiffer bolt return spring to compensate. My is chambered in 9mm so your mileage may vary. I have to thank Scottjua for the lubricated ammo trick, it improves feeding reliability immensely.

    Initially there was no cycling problem, but as the gun broke in it began to develop one. Old springs didn't last long. Changing to weaker ammo later in testing also caused some issues.

    Live fire video:
    https://www.youtube.com/watch?v=-cbtpQyXSYg
     
    Last edited: Jan 3, 2016

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