Sorry Guybrush, I didn't know anyone posted in here until now. My AR2 has deviated so much from the blueprints that they're no longer the same size, or much is referenced from it, but I think the AR2 blueprint measured 34 to 42 inches long (1050mm to 1200mm).
As for materials, I prefer using expanded pvc foamboard over others simply because it's less work than bondo and sanding, plus I have a hard time getting a consistent straight edge when I work with bondo, or any other sculpting materials.
Sorry for my long abscence with this project, I've had several other projects soaking up my time that made working on this project very difficult. I'm wrapping up the GS-221 CARB project and I hope to be working on this by the first of June, and hopefully I'll get it done before July (But is that likely going to happen?)
Here are some progress pics of my AR 2 thus far
I intentionally left the stock out of the photo, because there is some work on it that I don't want to reveal yet (specifically on how it comes together and details on the stock)
As you can see, I have most of the lower reciever completed, and yes, checkering the grip was a huge pain in the butt. I originally was going to stick a M16 style grip on it, but I decided against it and wen't with the alien reinterpratation feel.
Also I got another project along the lines of the AR2, It's appeared only once in the HL2 series, and the barrel is about 1 and 1/8 inch thick. Yes it's a beast. I'll show pics of it in this thread, since I don't have an official name for it. I don't have the peices ready to show yet, but theres something for you guy's to look forward to.
But yeah, once again, expect to see this thread moving again here shortly. Thanks for all of your interest, and as usual, questions, comments and critiques are welcomed.