heavy metal POTC Zizzle conversion

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 ***).


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Second step:

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

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Let it dry some minutes - Gypson is getting hard very fast.

Open the two halves CAREFULLY and remove the zizzle cap gently.

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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 !!!!!

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raw result:

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Fourth step:

Cleaning & trimming:

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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 :

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Now my gun is some Gramm heavier than yours :lol



I relaxed from Gypsom and made some flat parts.

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I really recommand you this sort of forming sand (20 bucks with steel frame & Talkum powder)

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...it's cheap and very easy to handle.... Ragetti could do this with two wooden eyes.

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... and the thrill is really awesome - great for all of you who badly need fast success

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Gotcha - first attempt was simply perfect :love

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same for the right side plate....

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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

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Hell it was a long night - fare well good old Zizzle side plate :unsure

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Took an hour of concentration but I am pleased so far with the result:

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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 :

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trigger guard

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trigger & hammer screw

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I removed the upper claw of the Zizzle hammer and will make this separate, so I can screw in some stone.

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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 :)

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Zizzle barrel cut away - now have to think how to close the big gap LOL

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Sunday afternoon barrel manufactoring :

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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.

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added the upper frame and filled it

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plastic barrel removed and only bamboo stick back in the mold again

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that thing needs a bunch of tin....now time is running veeeeeeeerrrrrrryyyyy slowly at my Worlds End .....

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...excitement....

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removed the sand and Bamboo stick - not too bad - some imperfections but these will be "repaired" with tin later

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nice barrel hole - hoorrray

Will clean it up tonight.



now it looks much more like a barrel

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have to put some counter-weight into the grip now LOL
 
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Wow such major work on a toy gun! It looks great and if you do decide to make the wood parts, you have metal parts all ready to go!
 
******* This is fantastic! Been lurking through the progress on KttC, and its phenominal how much of a difference the metal parts make, in pure look alone!
 
yepp - a lot of work for a toy gun but still a bunch of fun to do.



so this section could be useful to all Zizzle owner to let the hammer mechanism work like on real flintlocks :
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hammer down

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hammer ******


For the modification you only need a little screw as stop and your trigger and hammer is working like the real deal.

Check red circles - the screw is holding the trigger in correct place.

Cut/trim the "nose" of the little black plastic greebly at the trigger (NOT at hammer) just a bit.

And here ya go : cock the hammer by hand and press the trigger to let it go.
 
Wow, simple but effective. I'd never thought to use tin for the casting. You should make a zizzle conversion kit or something, you'll make a killing. I was considering painting up a zizzle flintlock but wasn't happy with having to settle for painted metal. That said great work, add to favourites.
 
Wow! I just started getting into metal casting. I've only cast into open-backed silicone molds. What are you using for your two-part molds (like the barrel). Did you build that casting box? (And, if so, what are the details.)
 
....throw plastic away ???? ....

Well....but....I cannot do.... can't change the title of this thread LOL

Hmm, why not - have some lime-wood lying around in my chaos workshop.

Tomorrow is Father Day and I don't join the alcoholic caravans with their wooden hand waggons here in Germany - so will have some drinks tonight and do some woodworks instead :)

The casting box for the barrel is simple as you see on the image - All two-parts molds I made with sand except the butt plate cus it was too deep for sand molds.

The hardest part was the barrel indeed - first I tried a metal tube for the barrel hole but it was cooling down the tin too fast - bamboo is working excellent - easy to remove out of the tin.

Actually I used the metal casting box which came with the sand but barrel was far too long for that one and I had to built a proper one myself.

If you want more shiny parts you can use Zamak which is much harder then tin (see Denix guns) - you can polish it up to chrome if you like.
 
Beautiful work! There's not much left of the Zizzle. You've stripped it down to its bare necessities. This build is crazy in all the right ways. Haha Great job!

Does anyone have any recommended suppliers online for metal casting supplies, including raw Zamak?

I have a few projects that could really benefit from this type of construction.

Thanks.

-Nick
 
Damn'd - I HATE this board - each time I got new ideas :lol


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I know it looks NOT like 3 hours of work LOL

This is following a new set of metal parts I'm afraid - now I can build a correct side plate with the peak corner to the left - that was impossible to do with the Zizzle......but now.


Zamak is available here on the Bay - you can also melt down some of your kids Matchbox die-cast cars but please with breathing mask.....danger of zinc fever....
 
Oh HELL YES!!!!! This is gonna make me wanna do a wood/metal one! And I have another Knock off Zizzle on the way too!!!....
 
thanks - specially for the wooden kick :)

For my new wooden friend I made a quick copy of the butt cap in Zamak - guess this would be one of your next suggestions right? LOL

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pure result out of the mold

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after 5 minutes polishing with a Dremel it looks much more shiny than tin

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left Zamak - right tin

note the little imperfections - that`s the reason why it`s better to make a gypsom mold instead of sand for the buttcap

Zamak is cool - quiet hard - no way to scratch it with my finger nails
 
That is really cool! I've thought about painting up one of the POTC guns, but not about going to all that work!
 
Fantastic thread and just super cool work! I wondered if you'd be switching to wood! This is going to be the envy of many!

Rich
 
made my final butt plate out of Zamak for the wooden replica now - this time with eyes (sand molded worked well this time)

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I decided to build a working lock mechanism so I separated the one-piece-Zizzle-block into three pieces : pan, frizzen, frizzen spring

Here is the cleaned Zamak frizzen - maybe a bit too shiny for a pirate pistol LOL


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