COMPLETED! Live fire DL 44 Mauser & DEC based

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ktflory

New Member
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.

Untitled by Kris Flory, on Flickr

Untitled by Kris Flory, on Flickr

Untitled by Kris Flory, on Flickr

Untitled by Kris Flory, on Flickr
 
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scottjua

Master Member
RPF PREMIUM MEMBER
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.
 

LB66679

Well-Known Member
RPF PREMIUM MEMBER
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 !
 

ktflory

New Member
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.
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.

Untitled by Kris Flory, on Flickr
 
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scottjua

Master Member
RPF PREMIUM MEMBER
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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ktflory

New Member
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.
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.
 

ktflory

New Member
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.

Untitled by Kris Flory, on Flickr
 

Halliwax

Legendary Member
RPF PREMIUM MEMBER
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?
 

ktflory

New Member
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.
 

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ktflory

New Member
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.

Untitled by Kris Flory, on Flickr

Untitled by Kris Flory, on Flickr
 

ktflory

New Member
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!
 

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russellsch

Sr Member
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.
 

ktflory

New Member
Re: Build in progress: Live fire DL44 DEC kit

Mystery disc!

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.

Untitled by Kris Flory, on Flickr
 

ktflory

New Member
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.

Untitled by Kris Flory, on Flickr
 
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