Evil Dead II/Army of Darkness replica chainsaw

Thanks man.
If I had an investor, I'd mold and cast the whole thing and do a full resin replica in essence of NECA replicas.
Problem is, the silicone mold would cost around 200 bucks and a resin pull would be the same. Doubt someone would be willing to pay four hundred dollars for a blank resin pull of the chainsaw... When actually once I get the mold made, I can make a bajillion resin pulls. Slush casting with resin has never been my talent though, ruined many mask projects doing such.

I'm totally going to pursue it one day though, having resin pulls of the chainsaw would rock and benefit me financially on ebay in the future.

Only down side is Evil Dead chainsaws dot com is going to be back in 2013. So people willing to shell out 500 bucks will be able to have a way better chainsaw than I have made.
 
As far as my saw goes, I'm done minus the addition of the grill and the paint and gore.

Pics up as soon as I get and slap the grill on the beast and then it's on to the distressing phase.

Can I get a hell yea?
 
What size dowel are you using for the pull handle and 1/2 on either side of the metal handle? 25mm diameter?

Don't remember specifics, that work was almost a year ago now.
Looking at how the saw turned out though, I'm thinking of doing another after this prototype and improving on a few little hiccups I've had along the way, like the severe importance of measuring where the hell your bolts will be going, especially on the top plate that connects tot he blade mount as the right pilot hole is a bit too far to the right which is making a huge inconvientient difference.

Another thing I'm going to change the next time around is the way I cut the actual chainsaw body. Cutting it exposed to show the "engine" like in the moving is totally not necessary and only makes visible gaps. Next time I'm going to just cut the root area of the top plastic handle off.

Also thinking about casting the whole side exposed engine area as a resin kit for fellow Evil Dead chainsaw replicators so you guys can take your saws to cons without any issues in the safety department. Maybe. Depends on how many inquiries I get on said subject.

Biggest concern is completing my prototype!
 
Don't remember specifics, that work was almost a year ago now.
Looking at how the saw turned out though, I'm thinking of doing another after this prototype and improving on a few little hiccups I've had along the way, like the severe importance of measuring where the hell your bolts will be going, especially on the top plate that connects tot he blade mount as the right pilot hole is a bit too far to the right which is making a huge inconvientient difference.


I didn't cut the top of the saw body under my top plate for three reasons. 1. I was running out of time, 2. I'm lazy, 3. I realized the same thing, that it would never be exposed, and even if it did, you would not see the internals of n actual saw like the movie.

Homlrunner - 25mm (1 inch) dowel rod for the handle and pull start.
 
Yeah, cheers guys. I thought 25mm looked about right, so that's what I used. Now I have the handle all finished (what a pain it was slicing the dowel in half with just a dremel!) and the pull handle added. Just need the T-clamp I ordered to turn up and to dismantle the engine (and paint!).....
 
Yeah, cheers guys. I thought 25mm looked about right, so that's what I used. Now I have the handle all finished (what a pain it was slicing the dowel in half with just a dremel!) and the pull handle added. Just need the T-clamp I ordered to turn up and to dismantle the engine (and paint!).....

Have you figured out how you're going to make the exposed engine area piece? Und which top plate/plastic lid piece you're going to attach the dowel handle to??
 
I went against my nature on this one (lazy) and cut it down with a hack say and 2 Dremels (yes, I smoked the first one at about 75% done). this took me about a week to do I think with limited time to spend each day (and one "sick" day), so this may have been where lazy started, hence not cutting the top plastic.

I like the look and functionality of your cast piece, but I had not worked with resins before and did not know how to mount well and support the chain bar and chain I used.
 
Wow, that saw just looks gorgeous. It's really coming along nicely, I can't wait to see it completed.

Here are a couple of pics of the grill castings. Now these were never intended to be "perfect" pieces. My original was made as a quick and dirty part. It is intentionally flawed with pits to emulate dents and gouges I intended incorporate into my weathering of the piece. And though the ribs are evenly spaced they are not all standing at perfect 90 degree angles, again it was intentional to add to the used look of the piece when finished. I only say this so that interested parties are aware of these things.

Here are the pics. First off a group shot...
castings01.jpg


Next up is a shot of a cleaned up and primed casting (black) next to my original piece (grey). I used black vinyl dye as a primer.
castings05.jpg


And here is the primed casting on the saw.
castings04.jpg
 
Pete, you are far too biast. Your grill pieces are by far the best I've ever seen. Those that are fortunate enough to get their hands on a copy of your amazing work are going to be some lucky sons of bastiches.

Cannot wait to slap one of these onto my saw!
 
OK, finally some pics of my own to show! Fantastic thread BTW - it's been a big help, so THANKS! :thumbsup

I decided to keep the metal blade mounting section for my saw, so took to dismantling the engine. As this was the one area that I was least sure about (as there's not been any pics of this part uncut posted yet) I took some pics pre-cut.

Using just a screwdriver and a bolt-unscrewer (whatever it's called! :lol) the engine can be taken apart to leave this section:

ED2Chainsaw2.jpg


ED2Chainsaw.jpg


I then spent AGES (probably 2-3 hours) cutting out the unwanted section. With proper tools (like, a bandsaw) this would not be too hard, but I just had my dremel, a drill and a junior hacksaw. I left the top and bottom sections that the bolts screw into so that the chainsaw bar can be held nice and tightly. I also popped in a hollow metal tube for the inside handle, but having tried it with the chainsaw bar attached (it's heavy!) I think I'll replace this with a thicker wooden dowel for a better grip.

ED2Chainsaw4.jpg


And just to show what I did with the other half - I cut out a circle from a large plastic dome I had and painted it matt black so your hand can't be seen from outside, but the curve of the dome allows the pull-string attachment to rotate freely without rubbing.

ED2Chainsaw3.jpg


Going to cut some metal into shape to fill the rest of the exposed side next...
 
OK, finally some pics of my own to show! Fantastic thread BTW - it's been a big help, so THANKS! :thumbsup

I decided to keep the metal blade mounting section for my saw, so took to dismantling the engine. As this was the one area that I was least sure about (as there's not been any pics of this part uncut posted yet) I took some pics pre-cut.

Using just a screwdriver and a bolt-unscrewer (whatever it's called! :lol) the engine can be taken apart to leave this section:

ED2Chainsaw2.jpg


ED2Chainsaw.jpg


I then spent AGES (probably 2-3 hours) cutting out the unwanted section. With proper tools (like, a bandsaw) this would not be too hard, but I just had my dremel, a drill and a junior hacksaw. I left the top and bottom sections that the bolts screw into so that the chainsaw bar can be held nice and tightly. I also popped in a hollow metal tube for the inside handle, but having tried it with the chainsaw bar attached (it's heavy!) I think I'll replace this with a thicker wooden dowel for a better grip.

ED2Chainsaw4.jpg


And just to show what I did with the other half - I cut out a circle from a large plastic dome I had and painted it matt black so your hand can't be seen from outside, but the curve of the dome allows the pull-string attachment to rotate freely without rubbing.

ED2Chainsaw3.jpg


Going to cut some metal into shape to fill the rest of the exposed side next...

Amazing job!
Your saw is already kicking mine in the rear as far as quality.
Can't wait to see more!
 
Been working on finishing this bad boy off for a while now.

I replaced the thin metal inner handle with the thicker wooden dowel that I had used for the top handle and string-pull handle. I used my dremel to cut a piece of steel to the correct shape to fill in the other half of the missing side (I drew, cut out and modified a card template first to get the shape right) and hot-glued it in place. Then drilled a hole in it to attach the black box type thing to it on the outside. Also got a long bolt to attach the wheel that makes the chain spin onto the side.

ED2Chainsaw4-1.jpg


ED2Chainsaw5.jpg


ED2Chainsaw6.jpg


From here, I've since finished it up (nearly completely). I bought a generic chain bar and chain (I had to dremel both to get them to fit together on the the chainsaw body properly. Used the dremel to sand down the chain bar to remove all paint (with text) and was left with a really shiny metal bar. So that was then painted to look rusty.

Have also built the arm cuff and attached it. Those T-clamps are a real PITA to make holes in! Even with my titanium drill bit it was a chore. All in all, it's now finished - except for weathering the actual chain and adding the round grill. I'm trying to get hold of one of PeteVenkman's grill pieces, but have had no reply yet. :(

Then have to decide to add blood/gore....
 
Yeah, I was doubtful that it would be possible without some heavy duty tools (like an industrial bandsaw), but with patience, a lot of fiddling about and just those tools, I managed it.

Here's were I'm at just now (not made any progress since my last post):

ED2Chainsaw8.jpg


ED2Chainsaw7.jpg


Looking forward to getting that grill. :thumbsup
 
That is looking positively lovely. It's a shame that once you get a hand inside there's not much room for other machinery, because it'd be great to hook up the biggest motor you could in there just to get a bike chain moving. I expect that'd be prohibitively heavy by the time you were done, though.
 
Yeah, I was doubtful that it would be possible without some heavy duty tools (like an industrial bandsaw), but with patience, a lot of fiddling about and just those tools, I managed it.

Here's were I'm at just now (not made any progress since my last post):

ED2Chainsaw8.jpg


ED2Chainsaw7.jpg


Looking forward to getting that grill. :thumbsup

outstanding job, man.
you are a freaking MASTER at distressing.
any tips??
i'm probably going to paint mine once I mold the whole thing in case anyone is interested in a kit of the saw or a complete resin copy that's safe for cons.
 
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