This may be jumping a bit ahead but what kind of base/stand do you plan to have for it? D:
Seems like it will be a lot more troublesome to put down or store than the Portal Gun.
I was planing on doing an acrylic stand similar to the one I designed for my N7 rifle. There's a shop here in Atlanta that takes custom orders for stands like these. They're a bit pricey, but they really show off the finished piece well:
Been fighting a cold off and on, so progress has been a mite bit slower than I'd hoped. Nonetheless, progress continues.
Added the battery tray to the upper side of the gun. The illuminated "vent" will cover this eventually, and will be held in place with magnets. Still needs the actual battery holder, but I forgot to order that with the rest of the parts from DigiKey a few days ago, so its on hold.
I had been struggling in my mind with the best way to get the rear pucks to fit into the back angled portion of the gun body. Trimming cutouts on the body itself had me worried, because I don't think I could get the two to line up perfectly. I decided the pucks themselves needed to be cut.
The blueprint here was based on the 3D model giving me the exact profile shape of the rear body. The jig slips over a PVC pipe, and I used my bandsaw to trim out the pucks to shape.
(These were test pucks; dud castings. I swear my rotocast skills don't suck that much!)
The finished result: