My Mal Pistol Project

[DrewSmith007]

So I think I have the solid model drawn up to the final version. It's taken several ground up revisions, but I think this is as close as I'll ever get without access to the actual gun.

The base pistol will be a cut down taurus model 94 in 22lr.

I'll be printing the brass pieces on my reprap and cleaning them up. I'll then enlist the help of a jeweler friend of mine with investment casting of those pieces. I've cast aluminum, but never brass, so that will be interesting.

The grip frame will probably be waterjet cut, or possibly machined by the guy that did my dexter knives.

I've got a CNC router that's about 50% done, based on the momus design. I'll finish building it, then I'll use it to cut out the grips. I'll probably also use it to build a jig to hold the pistol and grip frame in place while they're welded together.

There's no trigger or guard because the method I used to get the contour of the pistol into my CAD program wouldn't give an accurate shape, so I just left it out.

Anyway, this project will be a slow mover, so don't expect a ton of updates. I'm also open to criticism, so fire away!

 

[DrewSmith007]

And before anyone asks, there is absolutely no chance for any kind of kit.

 

[Triciareh]

Thats looking pretty awesome man

 

[Talos]

Very shiny! I've actually been teaching myself CAD and modeling for this exact project too... (not for a kit either, like you). You're way ahead of where I am, though.

 

[TheRambler]

And before anyone asks, there is absolutely no chance for any kind of kit.

Haha, I hope this works for you. I can already see all of the requests from the people who didn't bother reading a word of this thread.

Either way this is really awesome. Mal's is one of the coolest iconic pistols and it looks like you're well on your way to having a nice replica.

 

[MooMooEgg]

I love seeing Mal pistol builds, and I hope this one turns out well. I'll be keeping an eye on it, and good luck! :thumbsup

 

[Beergut]

And before anyone asks, there is absolutely no chance for any kind of kit.

Well thanks for kicking my hope in the balls. :darnkids

Just kidding, best of luck with your build, make sure to take lots of pictures.

 

[Tom Starkiller]

Oh, this should be good.

 

[airhead]

Don't forget to allow for shrinkage of the castings....

 

[Bodie27]

Awesome just awesome

 

[DrewSmith007]

Thanks for the compliments. I'm itching to start printing, but my printer is still down.

 

[DrewSmith007]

Here's a video update. I've got most of the pieces printed, but they still have to be finished.

I've decided to go ahead and build a plastic/resin version because I'm going to Dallas Comic Con in May and Nathan Fillion will be there so I want to get it signed. The brass project is still in the works, but I'm not going to concentrate on it at the moment. Plus, I won't be able to cast the pieces until summer anyway, so I guess it works out.

Sorry for the noise in the background, the printer is printing the barrel...

MVI_6463 - YouTube

 

[Too Much Garlic]

Awesome project. Well done.

 

[Felgacarb]

Nice! That is looking like a pretty solid assembly.

 

[The Cog]

This looks like a fun project! It would be great to see some more process pictures.

 

[freshmattyp]

Very impressive. Looking forward to seeing the completed piece.

 

[DrewSmith007]

Here's the finishing work I've been doing. This result is after at least 10 sand/fill/prime cycles. The green print is a pretty bad example, I forgot to modify the printer code for a slightly smaller filament, which makes the print lines further apart than they should be. It'll work out OK in the end though...

 

[pennausamike]

Here's the finishing work I've been doing.
This result is after at least 10 sand/fill/prime cycles.
The green print is a pretty bad example, I forgot to modify the printer code for a slightly smaller filament,
which makes the print lines further apart than they should be.
It'll work out OK in the end though...

http://www.therpf.com/members/drewsmith007/albums/random-prop-stuff/21626-img-6504.jpg

That's weird, I don't see any pictures in your post,
but an URL came up when I hit "reply with quote"
WTH.....

Mike

- - - Updated - - -

And still no pic.
Site upgrade just not workin' out for me.

 

[DrewSmith007]

Hmm, weird. The URL for the image has changed. Weird. Fixed though.

- - - Updated - - -

And no real updates. I've printed most pieces, and finished about half of them. I'm moving in a couple months, so I've been packing stuff that causes messes so I'm less tempted to make a problem I'll just have to clean up.

Hopefully I'll be able to buy a house soon, and be able to have a permanent shop set up which should help me get some of my projects done! Look for updates sometime in July.

 

[DrewSmith007]

Wow, it's really been that long since I updated this? So much for July...

I didn't get the plastic version done, and Nathan cancelled last summer's Dallas Comic Con. Buuut, he's going to be there this year... I've been experimenting with brass casting, and it went very well until I overheated my oven and it basically disintegrated. Here's the oven, pre-meltdown.





And the first cast, cooling:


and finally, the first casting mated in place with the plastic pieces.


I've got a long way to go, but I think a vacuum casting setup, professional grade investment, and a proper wax burnout method should increase the quality of the casts.



Anyway, I ponied up for professional high res prints of all the part's. They're scaled up based on the data I had from my casting projects.

I've got the silicone on its way to mold these. The mag is already in a mold box, and the unfinished pieces in this shot are extra's that I included to show how they looked before I finished them.



I also built a vac chamber to degas silicone, and I'll use the pump for a vacuum casting setup for the brass.

Still to go:

Either buy a ready to go melting furnace, or build another.

Buy a wax injector. I tried to make one, tried to use syringes, and in the end decided I don't have time to mess with it.

Build a burnout oven. The temps for this aren't anywhere near brass melting, so it doesn't have to be as heavy duty. Plus, they're very expensive to buy.

Develop a vacuum casting system, or buy one. Again, not very complicated and very expensive for what they are. But it comes down to time vs. money...

I also still have to sort out the steel handle modification. I've already got it designed, and can't decide if I want to have the whole thing CNC machined, or waterjet cut the profile and machine the scroll on the bottom myself...

The wood handles should be the easiest part, I've now got access to a CNC router that could whip them out in about an hour.

AAAand, the barrel tube. I'm thinking I'll go with a barrel extension on the stock barrel, to retain as much safety as possible.

Thanks for looking!