Jango Fetts Westar 34 (scratch built)

[Johannes]

Hi everyone,


I'm currently working on a replica of Jango Fett’s WESTAR-34 blasters. I'm relatively new to prop making and machining, so much of this process is a learning experience for me. I know the final finish probably won’t be as clean as I’d like but Ill learn a lot


Handle Build:


I started with the handle, using some MDF I had lying around. I shaped it using rasps, files, and sandpaper. Getting a smooth surface finish turned out to be quite a challenge—the MDF soaked up a lot of filler, and I had to do several rounds of sanding. If I were to do it again, I’d probably choose a different material.

The next step was making a silicone mold, which was another first for me. Despite not having access to a vacuum chamber or a pressure pot, the resin casts came out relatively well. There are a few bubbles here and there, so some post-processing will be needed.

For the machining part of the build, I started with the flash hider. The surface finish turned out pretty decent, though the drilled holes could be cleaner so Ill be doing some more sanding and polishing later on. The barrels also came out okay. The slots aren’t as clean as I’d like, but they’re passable for a first attempt.

Next up will be machining the flat parts—things like the trigger, the details on the underside of the handle, the brass parts and the rear section of the barrel. Once those are done, it'll mostly be a matter of final sanding and polishing.


I'll keep updating this thread whenever I get the chance to work on it which is unfortunately not as often as I’d like.

If you have any thoughts or tips and comments on my process I'd love to hear them

 

[PoopaPapaPalps]

I wish you luck on these! I've had ideas on doing this myself as I can make cast metal grips and am really wanting to just do it for that. I'll be watching this thread with great interest!

 

[Johannes]

Alrighty, a little bit of progress today. Got the Machining of the triggers and the stands (?) done and most of the filing (did the rough shapes on the mill and then the finer shapes and chamfering by hand. Still lots to sand and polish but I am starting to get most of the elements together now.

 

[Cbstudios]

These are looking super cool. Jango's blasters were always one of my favourite designs
]

 

[Johannes]

Some more progress yesterday, mainly working on the power regulator on the lathe. Really getting more efficient with it and starting to get much better surface finish.

 

[Johannes]

So, really good progress this week. I finished the machining on the Power Cell Cartridge and started putting everything together.
What's left now is the base of the handle as well the emitter for the second blaster which I will hopefully finish this week. After that it's mainly polishing and painting the handles.

 

[Johannes]

Sooo, closing in on the finishing line
Used a CNC mill for the first time to make the bottom parts of the handles and finished up the remaining parts as well as polishing most of it.
I also found a guy with an airbrush so we'll start painting the handles next week.

 

[Jamesfett]

Just wow!!!!!!!!!!!!!!

 

[Jamesfett]

Would you ever consider a run? Maybe kits?

Dark Energy Creations stopped offering these and the MR are very expensive.

You would probably have a lot of interest.

 

[Johannes]

I'd love to but I only have access to manual machines (other than a tiny cnc mill) and I worked on these things since February so there's no way I could offer these at a reasonable price

 

[Jamesfett]

I'd love to but I only have access to manual machines (other than a tiny cnc mill) and I worked on these things since February so there's no way I could offer these at a reasonable price

Crap

 

[DrToothache]

Wow, amazing job on these!

 

[Reel Fakes]

Insanely nice job so far, but you should enclose one of the trigger guards so you can twirl it!

 

[Johannes]

Crap

So I've been thinking about this a bunch since you asked and started making a Model and talking to some shops and I might actually be able to make this happen if there is enough interest!
I think those would be better quality than what I made because my 3Dmodel is more accurate than my machined version and they won't make as many mistakes as me when hand-machining.
Just need to think about if I want to offer these as a Kit that requires assembly, sanding and polishing for cheaper or a finished prop that will take a lot more work from my side.
Anyway, thought you might be happy to hear that
Here is a preview of the CADmodel

 

[eethan]

Nice work on the model,
if you are open to feedback, you can put much larger bevels on the handle. you'll also notice the top of the handle has a much larger and flater bevel than the rest of the handle.
And, the holes in the emiter can be bigger and at a larger diameter to be further from the end, as of now, they are too much at the front.
good luck with the project

 

[Johannes]

Nice work on the model,
if you are open to feedback, you can put much larger bevels on the handle. you'll also notice the top of the handle has a much larger and flater bevel than the rest of the handle.
And, the holes in the emiter can be bigger and at a larger diameter to be further from the end, as of now, they are too much at the front.
good luck with the project

Hi Ethan! Of course I am open to feedback, thank you so much! Really great spot! Ill update those points

 

[eethan]

Hi Ethan! Of course I am open to feedback, thank you so much! Really great spot! Ill update those points

Awesome
The opening on the barrels are a bit too wide (vertically) as well.
Cheers

 

[Jamesfett]

Yes!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!



Two please.

 

[Johannes]

Haha, happy to oblige

 

[Johannes]

Alright, so I adjusted the things you mention, it's really tricky to get the holes in the emitter right since Size of the hole, placement of the hole and the curve of the emitter all affect it but I think I got it matched up quite well now with the refernce (also taking into account that the image from the Visual Dictionary has a fair amount of perpective distortion in it.
But please if you notice anything that doesn't seem right, it's super helpful!