Pulseriflefan
Well-Known Member
Ahoi !
Loooooong time no talk, so I thought I post some images of one of my many projects....
After playing with my Zizzle I thought it's could be a bit heavier LOL
So I started with the butt cap
First step:
steal some Lego bricks from you kid and build a little frame.
Get some shoe polish and apply it on the plastic butt cap - not to much - you don't want to loose any details.
Mix up some fine grain gypsum and fill it half into the frame - knock it on the table to let the bubbles go.
Apply directly some Gypsom with a brush on the deeper areas of the Zizzle butt cap.
Put the the butt cap with the face looking down into the gypsum (*** please NOT faced up like my first try on the image ***).
Second step:
after the first half dried apply some shoe polish on the gypson also and fill up the form completly.
Let it dry some minutes - Gypson is getting hard very fast.
Open the two halves CAREFULLY and remove the zizzle cap gently.
Third step:
carve two small air pipes into the gypsum block and an inlet opening on top for the tin.
MAKE SURE YOUR GYPSUM IS REALLY REALLY REALLY DRY BEFORE YOU POUR MELTED TIN INTO YOUR FORM !!!! DANGER OF EXPLOSION - NOT FUNNY !!!!!
raw result:
Fourth step:
Cleaning & trimming:
Your form is actually a "lost form" - that means you can use it only once maybe twice if you are carefully enough when you remove the tin butt cap out of the form.
Now grab your Zizzle and trim the cap until it fits your gun :
Now my gun is some Gramm heavier than yours :lol
I relaxed from Gypsom and made some flat parts.
I really recommand you this sort of forming sand (20 bucks with steel frame & Talkum powder)
...it's cheap and very easy to handle.... Ragetti could do this with two wooden eyes.
... and the thrill is really awesome - great for all of you who badly need fast success
Gotcha - first attempt was simply perfect :love
same for the right side plate....
and the thumb plate.
Make sure to remove the Disney logo of the side plate first LOL
Tonight will be the night of the long knives - I will try to install the right side plate to the Zizzle - so I have to hurt my fellow Zizzle :cry
I am using a gas torch and soup ladle from Kwik-E-Mart
Hell it was a long night - fare well good old Zizzle side plate :unsure
Took an hour of concentration but I am pleased so far with the result:
Good Lord it worked - I just realized that I cannot make any castings of the real side plate after I dremeled it away LOL
Some more raw parts are ready to clean-up - all were made with the sand form :
trigger guard
trigger & hammer screw
I removed the upper claw of the Zizzle hammer and will make this separate, so I can screw in some stone.
Hardest part so far - took three tries.
First I thought to separate and modify it to a working lock but better to do this for my firing one later.
Maybe a solid resin copy of the "wooden" Zizzle parts would be a great add-on - have to think...
parts installed - weight feels quiet good
Zizzle barrel cut away - now have to think how to close the big gap LOL
Sunday afternoon barrel manufactoring :
The thing in the sand mold is the slightly modified cutted end of the Zizzle barrel.
I hot glued an alu tube under the plastic barrel, put the orange tip on top and inserted a stick of bamboo wood.
added the upper frame and filled it
plastic barrel removed and only bamboo stick back in the mold again
that thing needs a bunch of tin....now time is running veeeeeeeerrrrrrryyyyy slowly at my Worlds End .....
...excitement....
removed the sand and Bamboo stick - not too bad - some imperfections but these will be "repaired" with tin later
nice barrel hole - hoorrray
Will clean it up tonight.
now it looks much more like a barrel
have to put some counter-weight into the grip now LOL
Loooooong time no talk, so I thought I post some images of one of my many projects....
After playing with my Zizzle I thought it's could be a bit heavier LOL
So I started with the butt cap
First step:
steal some Lego bricks from you kid and build a little frame.
Get some shoe polish and apply it on the plastic butt cap - not to much - you don't want to loose any details.
Mix up some fine grain gypsum and fill it half into the frame - knock it on the table to let the bubbles go.
Apply directly some Gypsom with a brush on the deeper areas of the Zizzle butt cap.
Put the the butt cap with the face looking down into the gypsum (*** please NOT faced up like my first try on the image ***).


Second step:
after the first half dried apply some shoe polish on the gypson also and fill up the form completly.

Let it dry some minutes - Gypson is getting hard very fast.
Open the two halves CAREFULLY and remove the zizzle cap gently.

Third step:
carve two small air pipes into the gypsum block and an inlet opening on top for the tin.
MAKE SURE YOUR GYPSUM IS REALLY REALLY REALLY DRY BEFORE YOU POUR MELTED TIN INTO YOUR FORM !!!! DANGER OF EXPLOSION - NOT FUNNY !!!!!

raw result:

Fourth step:
Cleaning & trimming:


Your form is actually a "lost form" - that means you can use it only once maybe twice if you are carefully enough when you remove the tin butt cap out of the form.
Now grab your Zizzle and trim the cap until it fits your gun :



Now my gun is some Gramm heavier than yours :lol
I relaxed from Gypsom and made some flat parts.
I really recommand you this sort of forming sand (20 bucks with steel frame & Talkum powder)
...it's cheap and very easy to handle.... Ragetti could do this with two wooden eyes.
... and the thrill is really awesome - great for all of you who badly need fast success
Gotcha - first attempt was simply perfect :love
same for the right side plate....
and the thumb plate.
Make sure to remove the Disney logo of the side plate first LOL
Tonight will be the night of the long knives - I will try to install the right side plate to the Zizzle - so I have to hurt my fellow Zizzle :cry
I am using a gas torch and soup ladle from Kwik-E-Mart
Hell it was a long night - fare well good old Zizzle side plate :unsure
Took an hour of concentration but I am pleased so far with the result:
Good Lord it worked - I just realized that I cannot make any castings of the real side plate after I dremeled it away LOL
Some more raw parts are ready to clean-up - all were made with the sand form :
trigger guard
trigger & hammer screw
I removed the upper claw of the Zizzle hammer and will make this separate, so I can screw in some stone.
Hardest part so far - took three tries.
First I thought to separate and modify it to a working lock but better to do this for my firing one later.
Maybe a solid resin copy of the "wooden" Zizzle parts would be a great add-on - have to think...
parts installed - weight feels quiet good
Zizzle barrel cut away - now have to think how to close the big gap LOL
Sunday afternoon barrel manufactoring :
The thing in the sand mold is the slightly modified cutted end of the Zizzle barrel.
I hot glued an alu tube under the plastic barrel, put the orange tip on top and inserted a stick of bamboo wood.
added the upper frame and filled it
plastic barrel removed and only bamboo stick back in the mold again
that thing needs a bunch of tin....now time is running veeeeeeeerrrrrrryyyyy slowly at my Worlds End .....
...excitement....
removed the sand and Bamboo stick - not too bad - some imperfections but these will be "repaired" with tin later
nice barrel hole - hoorrray
Will clean it up tonight.
now it looks much more like a barrel
have to put some counter-weight into the grip now LOL
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