Denix Mauser Mods and ESB Blaster Re-Build WIP

Discussion in 'Star Wars Costumes and Props' started by matty matt, Jun 8, 2015.

  1. matty matt

    matty matt Sr Member

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    I've had this Denix for a long time, and it's way overdue for an overhaul. You guys know how bad these are. All the edges are extremely soft, pitting everywhere, etc. I've going to strip it down and sharpen all the edges, clean things up, and add some detail. I've got some old Blast-Tech parts I can reuse and a new knurled disk coming from Boba Debt's run.

    Before pics. Typical Denix. I'm getting rid of the left side greeblies.

    [​IMG]

    [​IMG]

    I got a set of the brass grip hardware on ebay for $5. I'll be sticking with the plastic grips for the time being since they fit correctly.

    [​IMG]

    [​IMG]

    I took everything apart and started to sharpen angles and clean things up. I'm filing everything by hand.

    [​IMG]

    [​IMG]

    Things are shaping up.

    [​IMG]

    Lots more work to do, but the results are pretty good so far.
     
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  2. DL 44 Blaster

    DL 44 Blaster Sr Member

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    Looking REALLY good so far!
     
  3. mortifactor

    mortifactor Well-Known Member

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    How are you doing the recessed panels by hand? I have a denix and am limited to hand files and a dremel.
     
  4. matty matt

    matty matt Sr Member

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    I'm in the exact same boat. Hand files and a dremel. For the recessed parts, I'm just going around the edge with a small grinding bit I had.
     
  5. Country Paul

    Country Paul Sr Member

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    Nice work, it's looking sharp

    just wish I had the patience (& skill) to go the extra mile with my Denix blasters
     
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  6. matty matt

    matty matt Sr Member

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    This is becoming quite the learning experience. I've never owned an MGC or anything, so I guess I never truly realized how bad the Denix is. It's kind of discouraging, but I'm staying positive!

    Here's a neat little tidbit. There are what look like two molded washers on the sides by the site. Guess what! They're not supposed to be there.

    [​IMG]

    And gone...

    [​IMG]
     
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  7. mugatu

    mugatu Sr Member RPF PREMIUM MEMBER

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    That's what I like to see, matty matt! I love the commitment!!! All the filing you are doing to correct this is looking great. It is really paying off, man.
     
  8. OdiWan72

    OdiWan72 Master Member RPF PREMIUM MEMBER

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    Keep the pics coming...love the WIP shots!

    Markus
     
  9. mortifactor

    mortifactor Well-Known Member

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    I agree, only just started to touch my denix and i feel like packing it in and finding an mgc somehow lol
     
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  10. matty matt

    matty matt Sr Member

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    I'll try to keep the updates coming! Nothing too interesting to report, just a whole lot of grinding and smoothing. The good news is that the pitting seems to all be pretty close to the surface, so it doesn't take a whole lot to get to nice metal. I worked on the bottom a little and drilled the hole for the button thingy. I did try to engrave the curved line around it, but it looked bad so I may just skip that.

    [​IMG]
     
  11. Crazylegsmurphy

    Crazylegsmurphy Active Member

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    This is looking great!

    It is inspiring me to do my own. Would you mind posting some photos of the tools you're using, and perhaps detail the technique(s) you're using to get these shapes?

    Oh...for the engraved curve, it might work to draw the shape on a piece of thick plastic, then tape it on in the correct position so you can use it as a guide to scratch in a starting line to work from.

    If you want, I can do up a shape in Illustrator that you can print and use as your guide for the plastic.
     
  12. mugatu

    mugatu Sr Member RPF PREMIUM MEMBER

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    matty matt, it's looking great. I am not familiar with the "engraved" part. Is it supposed to be around that hole on the bottom?
    Nevermind. You probably mean that line along the edge there. Did you do that?
     
  13. OdiWan72

    OdiWan72 Master Member RPF PREMIUM MEMBER

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    He is talking about the magazine bottom plate/ cover.
    It is meant to be a separate part, so the seamline between it and the mag well should be visible on real and MGC C96´s
    Check BobaDept´s JY thread for accurized Denix mausers and you´ll see what I am referring to

    Markus
     
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  14. halliwax

    halliwax Master Member RPF PREMIUM MEMBER

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    this is great info, thanks for sharing i never knew about the washers that have to be sanded. it sure is "shaping" up! ;)
     
  15. matty matt

    matty matt Sr Member

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    We must think alike, because that's pretty much exactly what I did! I tried to dremel the line but I didn't have the right bit, so it was all choppy and bad looking. Maybe I'll try again. Honestly, I'd rather it just not be there than than look bad or not right.

    OdiWan is right on the money. The straight line on the side comes on the Denix from the factory, but there's a curved line on the bottom that they left off (along with the button).

    - - - Updated - - -

    Lol, Shaping up indeed.
     
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  16. Crazylegsmurphy

    Crazylegsmurphy Active Member

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    :)

    I'm sure you've explored this, but the problem with the dremel is that, as you said, without the right bit it would be hard to control. If you score the metal deep enough using the template, it might create a groove that is smooth and deep enough to either finish with the dremel, or continue slowly by hand.
     
  17. matty matt

    matty matt Sr Member

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    You're right. The idea was good, but I blew it on the execution. Scoring by hand would probably be the way to go.
     
  18. matty matt

    matty matt Sr Member

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    Here's a particularly bad spot on my Denix. Soft detail and a big, ugly screw.

    [​IMG]

    Here's after a little bit of work. This is just filing with flat files and a light sanding. I am using a little grinding wheel on my dremel to smooth out the really bad areas.

    [​IMG]

    You can see I flattened the screw and countersunk it so it sits flush. There's a little bit of a gap between the upper and lower parts still, but it's not really a big deal to me. It's a lot better than it was.

    [​IMG]
     
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  19. mugatu

    mugatu Sr Member RPF PREMIUM MEMBER

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    Great pics and explanation! You are really whipping this Denix into shape man. LITERALLY!


    BTW, can I see a pic of the files you are using in relation to the Denix so I know what size they are?
     
  20. matty matt

    matty matt Sr Member

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    Sure! Here's pretty much what I'm using. I've got an assortment of files and I'll just grab whatever one I think will work for the particular area I'm working on. Just like with sandpaper, it helps to use a coarser file first and then a fine one for finishing.

    [​IMG]
     
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  21. mugatu

    mugatu Sr Member RPF PREMIUM MEMBER

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    Thanks, matty matt. That's quite the arsenal you've got there. I need to build up my file collection.
     
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  22. matty matt

    matty matt Sr Member

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    So I decided to give this another try and I think it worked, lol. This time I scribed the line by hand with a metal pick. It was a pain, and my fingers hurt, but I think I like it.

    [​IMG]
     
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  23. OdiWan72

    OdiWan72 Master Member RPF PREMIUM MEMBER

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    WELL DONE!!!

    Markus
     
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  24. Trilogy

    Trilogy Sr Member

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    Well done indeed. I've been wanting to do this myself on my current WIP blaster but am dubious about attempting it by hand.
    Already drilled the release button 1mm off centre, which to my eyes appears more like a mile. :facepalm
     
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  25. cayman shen

    cayman shen Master Member

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    Wow, steady hand!
     
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  26. Crazylegsmurphy

    Crazylegsmurphy Active Member

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  27. halliwax

    halliwax Master Member RPF PREMIUM MEMBER

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    coming together smooth!!


    Sent from my iPhone using Tapatalk
     
  28. ronwlim

    ronwlim Active Member RPF PREMIUM MEMBER

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    THAT is a thing of beauty. You have a steady hand!

    -Ron
     
  29. OdiWan72

    OdiWan72 Master Member RPF PREMIUM MEMBER

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    Will you be making it a MGC lookalike?
    Do you think you could incorporate a MGC trigger, given the internals of a Denix?

    Markus
     
  30. Sith_Lord_Hritz

    Sith_Lord_Hritz Well-Known Member RPF PREMIUM MEMBER

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    Great work !
     
  31. SydStryfe

    SydStryfe New Member

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    Looking great!

    Any thoughts on how you're going to finish it (paint, bluing, etc.), or is it too early to ask?
     
  32. matty matt

    matty matt Sr Member

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    This is more of just a cosmetic overhaul I guess. I'm not going to mess with any internal parts. I don't think there's too much you can do with the Denix parts anyway.

    Combo of both I think. I'll have to play around a bit. I had to fill some holes with JB Weld and I know that won't take the bluing.
     
  33. scarf man

    scarf man Sr Member

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    Fantastic job Sir!
     
  34. SydStryfe

    SydStryfe New Member

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    That's exactly what I was wondering, so I'll be very curious to see how the finish turns out after the appropriate modifications. I have an accurized Denix from one of Bobadebt's runs, but after seeing this thread I'm thinking of taking a file to those "washers" on mine as well. It's a small thing, but man what a difference.
     
  35. matty matt

    matty matt Sr Member

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    I know what you mean. But be careful, it's a slippery slope, lol. I'm going to try some different paint techniques. I'll keep you updated.
     
  36. matty matt

    matty matt Sr Member

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    I worked on the hammer a little last night. It's a little less "Denix" now.

    Before...
    [​IMG]

    After...
    [​IMG]
     
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  37. mortifactor

    mortifactor Well-Known Member

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    This is basically a better version of what I was going to do! I will copy this and save £300 on an MGC. Is it mostly hand files for re-shaping the hammer?
     
  38. matty matt

    matty matt Sr Member

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    Yep, all you need are some files and a little bit of time.
     
  39. matty matt

    matty matt Sr Member

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    Widening and reshaping the area behind the trigger guard.

    [​IMG]

    Tarnishing that shiny new brass with ammonia fumes.

    [​IMG]

    [​IMG]
     
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  40. mugatu

    mugatu Sr Member RPF PREMIUM MEMBER

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    How long did you hang the brass in the jar to get that level of tarnish?
     
  41. matty matt

    matty matt Sr Member

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    About an hour or so. When it starts to tarnish, it happens pretty fast. If you leave the pieces in too long they will turn green.
     
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  42. Sith_Lord_Hritz

    Sith_Lord_Hritz Well-Known Member RPF PREMIUM MEMBER

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    Do you remember the seller you got the brass caps from on eBay?
    The work you've done so far is awesome, I'm defiantly going to try this myself. Keep the pics coming.
    Thanks
     
  43. matty matt

    matty matt Sr Member

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    Thanks! The seller was gunpartscorp. The transaction was smooth.
     
  44. matty matt

    matty matt Sr Member

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    A few minutes with a torch and I was able to fix the bent barrel. I forgot to take a before pic but it used to go off to the side pretty badly. So much better now.

    [​IMG]
     
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  45. mortifactor

    mortifactor Well-Known Member

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    Looks impressive, do you have any details on how you got the semicircular detail on the bottom so exact? Did you also use a pillar drill for the hole at the bottom?
     
  46. DL 44 Blaster

    DL 44 Blaster Sr Member

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    Looking really nice! I don't think I've ever seen such work done on a Denix.
     
  47. halliwax

    halliwax Master Member RPF PREMIUM MEMBER

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    that sure is allot of filing. you have great patiences and it pays off, looks great!
     
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  48. matty matt

    matty matt Sr Member

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    To get the line, I glued an appropriately sized metal washer on the bottom. I used that as a guide to scribe the line. Once it was deep enough, I pried the washer off and finished things up. I just used a big countersink bit to drill the hole. Just a regular hand drill. Nothing fancy.

    Thanks! I've seen some great Denix mods on this site, and that's really what inspired me. The Denix is so bad, pretty much anything you do is an improvement, lol.
     
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  49. matty matt

    matty matt Sr Member

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    I cleaned up the knurling on the hammer and the bolt. They must mold a lot of these parts in two pieces because the knurling on the hammer didn't line up at all. I pretty much had to obliterate what was there and make new grooves with a small triangular file.

    [​IMG]

    Also started to reshape that blocky trigger.

    [​IMG]

    [​IMG]
     
  50. mugatu

    mugatu Sr Member RPF PREMIUM MEMBER

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    matty matt, you are making me want to get one of these.
     

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