Han Solo DL-44 Build - Broken Part Repair Advice

[Jasonvince1]

I'm working on my first ever DL-44 blaster build. I'm doing the ANH version. I was fortunate enough to pick up an MGC Mauser replica and a cast kit from Dark Energy. I am totally excited about my build. As I was getting started I field stripped the MGC Mauser and much to my surprise one of the parts disintigrated. I don't know what the exact name of the part is but it is the part that the barrel block latches onto. The hammer spring pushes up against it. I have included a picture below for reference.



I have some JB Weld on the way to make the repair. My original thought was just to join the pieces up and let the epoxy set. I'm having second thoughts as this part seems to bear a good amount of stress within the gun. It is a simple enough part that I'm considering casting my own replacement part out of JB Weld. Has anyone encountered something similar? Any recommendations on making a correct repair or tracking down a replacement are appreciated.

 

[Mara Jade's Father]

For either of your options, you still need to repair the part. I would plan on using the original fixed part but just in case, make a mold of it and have a casting ready to go.

 

[Darth Lars]

What part is it? I don't recognize it from any parts diagram ...

If that part is flat and not too thick then I would make a new one out of aluminium.

 

[Jasonvince1]

You can see where the broken part is located in this clip at about 2:13. It is the spring loaded piece he pushes back with the screwdriver. You don't actually see the part, but that shows you where to look. I don't have it in front of me right now but it is about 3/8 inch thick by about 3/4 inch long and pretty flat. Without it, the whole top barrel/slide has about 1/4 inch of play back and forth when reassembled..

 

[Jasonvince1]

Just to circle back and close this out, I rapaired the piece with JB Weld and reasembled. It lasted about 5 minutes. So I JB Welded it again and sent it off to be cast by Arnie Prince in Lodi CA. He does cast irom vintage toy work but the replacement part came back in great shape and reassembled without a hitch. It now keeps the slide firmly in place. Not a bad end result and only cost me $12 to have the new casting made. Now on to finishing the build ...