Portal Gun finally FINISHED!

TMBountyHunter

Well-Known Member
Hi everyone, I've been lurking for a while and finally decided to post.

So back last August I decided I wanted to have a Portal Gun for a con. That was kind of a last minute thing since I realized I didn't have any money to blow in the dealer room and the guest list didn't seem too fun. Regardless I wanted to go and get the most out of my weekend pass so cosplay was the natural choice.

This isn't meant to be a WIP thread yet (since schoolwork currently wants to kill me with sleep deprivation), but more of a short review of references to make the Portal Gun. Since my build was so last minute, with only 2.5 weeks before the deadline my first thought was to just copy Volpin's famous V1 gun but I quickly realized that as wonderful as his WIP post is it's quite far from a clear blueprint that you can just grab all the parts and slap it together.

Next choice was to go straight to the source (no pun intended) the game itself. Ideally the path would have been to just export the model to CAD software, tweak it, break it into parts and print out the plans and the shopping list. This idea was quickly canned because I had absolutely no clue about exporting models or CAD software and no time to learn with the deadline looming.

Moving on to the next option: Steam has built in SDK for most of Valve's Source Engine games and if you own the game you can just grab the SDK for free, which comes with the Model Viewer. Here came the first and biggest problem. The game actually has two different Portal Gun models: w_portalgun.mdl which is the low-polygon model used within the world (on the stand, the ground when you die, the one Chell is holding when you look at yourself though a portal, etc). And the v_portalgun.mdl which is the player view model, it has a much higher polycount but it's also incomplete since you only ever see it from one angle. The problem here is that the two models do not agree with each other, especially since the view model has a few gameplay tweaks to it so that it doesn't obstruct the player's view too much.

So there I was, 2 weeks to make the damn thing and no one true blueprint to follow. I ended up spending a weekend or so drawing up my own plans that turned out to be a Frankensteining together of the W and V models, the Volpin gun and at the same time trying to keep dimensions close to off the shelf pipe sizes.

Long story short I didn't finish in time for the con, this is what it looked like the night before:


Pause in build afterwards, some progress during Christmas break, and here's about what it looks like now:


As happy as I am with it, I always knew this is only a v1 and I'll get around to making a better, more accurate version eventually. What I didn't know until this past week or two was what my final reference would be for that "accurate" portal gun.

Portal 2 has been announced all the way last year before I started my gun, but all the promo images and video released have always had the same old portal gun models. It wasn't too bat of an assumption to make that the developers would update the weapon models for a sequel. But nope. The only variation was the Co-op bots had color stripes. Even as recently as February Chell was still carrying around the W model in new promotional art:


But then on March 17th something magical has finally happened. Valve released the 30 second TV spot for Portal 2 and right at the beginning what do we have? Why it's a shiny new, high polygon Portal Gun model!

Finally a proper reference! Too bad it's stuck in a trailer and at that point I just decided to wait and see what happens.


Yet there's more! Valve started the insane Alternate Reality Game on April 1st to promote Portal 2 and after a while concept art started emerging. While most images have the portal gun either roughly sketched or are reusing the W model, two images in particular I find relevant to the current topic of this thread. The first is this, which is quite literally a shiny and clean portal gun and a potential reference.


The other is this.

Looks familiar? That's a photo of Volpin's gun worked into the sketch.


But now for the grand finale of this post and pretty much the reason why I finally decided to post. I got home today to find that Valve released yet another promo video. Right at the beginning we have this:



Quite literally, THE blueprint. Every little bit in exploded view, even the obscured and mysterious bits. Sure it doesn't come without contradicting the previous models, but I'd say it's as definitive of a reference as it gets unless Valve included the TV spot model in the game for us to export and manipulate.



As far as my WIP goes I have dozens and dozens of pics but I also have a terrible habit of writing up very wordy posts documenting everything because I like to have people point out where I went wrong or what processes I can make more efficient. I'll probably get around to it in very late April.
 
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Re: Portal Gun woes

I am feeling you with the changes. The Portal Gun was really the first project I ever took on, and looking back at it now there are about a million things I need to change. To get the form right at this point would require an entirely new scratchbuild... which I'm hesitant to begin again.

That said, your gun looks fantastic - I especially like the front casing. Keep up the work - I'd really like to see it finished.

By the way, what did you use for the center tube area?
 
Re: Portal Gun woes

Thanks guys and sorry about lack of actual prop building pics.

That said, your gun looks fantastic - I especially like the front casing.
Noooooooooooo.... The front is what's been scheduled for a major retweaking......

Back in November when I was doing mockups to see what needs fixing the front turned out to be in the wrong place and a bit small.




By the way, what did you use for the center tube area?
The clear one? Acrylic pipe with 2.5" outside diameter and ¼" wall. Sized it based on overall center body width and a local plastic supply store happened to have something almost spot on, just in minimum 6' length :unsure

As far as for lighting up it up inside I still have no idea what I'll do. The video game models don't actually have a secondary small inside tube that lights up, just a path for the effects particle and it's been wrecking my brain trying to think of a way to replicate that in real life.

Detailed writeup probably next week after finals.


Keep up the work - I'd really like to see it finished.
Yeah me too. Staring at a primed piece of plastic for months is really annoying. New deadline is a con at the end of May so we'll see how things go.
 
Re: Portal Gun woes

Put in a polycarbonate tube with Corbin film and mount an orange LED in one end and you will have a "Beam" of orange light. It is the way lightsabers are made these days. Check out the Custom Saber Shop forums for a how to.:sleep:sleep
 
Re: Portal Gun woes

Portal 2 is finally out and it is glorious beyond expectations :love


On to the most important part, the Portal Gun changes. Originally I thought from the trailers it was just reskins but there is indeed a few minor changes to the V model: slight change in the front shell shape and thickness as well as a bit of a modification to the ends of the 3 claws and the top light in the back shell. The reskin is still there. Mostly adds wear, changes the decal placement but also adds a bit of detail.

Unfortunately the SDK is no available yet for Portal 2, so no model viewer unless someone manages to dig out the model files from the game and export them somewhere.

This leaves on the 1st person comparison for now, a bit difficult because of lighting conditions and slightly different position of the model.

Ye olde gun
"New" gun

One extra bit added to the ends of the claws


Now that finals are done I'll probably spend the rest of today replaying a few bits of the game and then hopefully start gathering all the old pics and writing the WIP posts.
 
Re: Portal Gun woes

Alright time for actual WIP post and let's get straight to it.


As mentioned in the first post I decided to work from the original Valve game models but couldn't be bothered to export them. What followed it taking lots and lots of reference pics in the Source SDK Model Viewer.



Afterwards there was a lot of sizing assumptions and accommodations for standard pipe sizes and a lot of pixel measuring to get the proportions approximately right. Rough plans drawn up on paper:



Originally I thought of scanning all the plans and posting them but seeing how inaccurate they are that'd just be a disservice. Whenever I'll get around to trying to make a properly accurate v2.0 gun I'll probably post those up if no one else beats me to it.

For raw materials I had some 1/8th inch acrylic and 0.060" styrene sheets laying around so those needed to be used up. Especially the Acrylic since I hate working with it. Appropriately sized pipes bought from hardware store and the clear acrylic tube from a local plastic supplier. So that's most of the raw materials.



I don't have too many tools so sometimes I have to improvise:




And then all the cutting and building starts. Front barrel and center body:



Combining the two



Obligatory confusion of inside and outside diameters:



The two side I was planning to build up with Bondo and a template for the shape. I've seen this trick with polyester putty done a million times on the internet and in hobby magazines:



In the end I screwed it up and had to cut down most of it



Did the other side with Apoxie



That turned out a lot better and I came back to finish the first one



The detail on the top rear of the barrel, initial layer



Then more Apoxie rolled over the top and carefully trimmed to try and get the detail right



Another shot of material being slowly built up



In the end most of the bits were built up with Apoxie and templates





Moving on to the rear of the gun, the beginning of where the front part will slide into:



Big pipe fitting cut in two parts



And a whole one with a screw cap at the very end. The screw cap got the handle and will be used to access all the electronic innards



The main body assembled



And priming in my spray booth






That's it for this post. Next one will be about the shells, claws and other small trinkets. I'm still trying to dig up all the pics from last August so this has taken a bit longer than expected.

Comments, criticism, questions all welcome :D
 
Re: Portal Gun woes - Now an actual WIP thread with pics

Thanks!

Seems I took fewer pics than I thought, but it should still be enough for most things.


So as the body was being built I started on the shells. Insulation foam was leftovers from other projects so that was some nice use of resources as well. First carved the rough shapes with a nice sharp blade:



Then the curves were sanded smooth. This didn't need to be perfect because it was just the start of a long and paintful process. The foam is undersized slightly because the shape will be built over it. After I was happy with the shape on went a few coats of gesso with light sanding in beteween to elimitante the bits that stick up.



Now for the actual shell beginning, a few good coats of Bondo long strand fiberglass filler. Rough sanding in between on the beltsander (the only properly powerful tool I have and I'm very thankful for it). After the Fiber Bondo coat is thick and strong enough the internal foam is cut and scraped away.



Here the mounting bracket is on already. Originally I planned to cut out the big chuncks of foam and then disolve whatever little was left sticking to the Gesso and Bondo but that made more mess than it removed. In the end scraping the leftover foam out with a rusty spoon was the best and easiest solution



On top of the fiber Bondo went a lot of regular Bondo. Really quite a ton. I'm a bit terrible at sculpting so the process was just many iterations of slapping on more Bondo and then trying to get a curve that looks right on the belt sander. Edges were also redefined a lot and I still don't think they're finalized.



Some holes in the fiber bondo also filled with leftover Apoxie from other processes at the time. A mockup of the shells:



Mounting the front shell turned out to be quite easy, just a chunk of metal. I've thought through many fancy ways of mounting the back shell but in the end I decided to go wtih just a chunk of wood. It's glued and screwed to the actual shell but screwed to the main body so that I can remove it easily:



Another detail was making the hole for the light have a nice edge. A super glue tube and some clay were used as a mold and resin poured in. Originally I tried doing this with bondo but that didn't work out, you can still see some of it left around.








Next up is the front claws and other bits

The plan was build one original for each piece and recast it. Originals are just styrene, bondo, apoxie and whatever else.



The plan quickly messed up when I found out my silicone has gone bad and was too thick to pour. I decided to stick the part into the mixing cup instead of trying pour it/



This turned out to be a massive pain in the ass and later I wished that I had just started over with fresh resin. Lots of bad pours, headaches and the mold was uselss by the end. I did get 3 fixable pours though.



Next up the middle bit of the claw, just styrene strips



The end of the claw recasting went a whole lot smoother with fresh silicone



The detailed bits inside the clear pipe, or aka Event Horizon Estimation Wheels are just acrylic doughnuts with recast bits.



They turned out kinda crappy in the end so I might remake them.





So here's all the progress so far, put together.



The detail around the clear tube is styrene, apoxie and some SGTP I think, don't really remember anymore and I don't have pics of the build steps unfortunately. The back ring is still not done though so you can see the raw apoxie.



The claw is crooked, so that'll need fixing



Over all pretty happy with it. Not perfect, gonna need a V2, but should still be awesome for a first attempt.




This was the state of the gun at the end of last year and I haven't had the time to work on it yet. I'll probably get back to doing actual work at the end of next week. I have another project running at the same time and that'll probabaly eat up some of my time.
 
Re: Portal Gun woes - Now an actual WIP thread with pics

Small update time.

Back shell is practically finished.


The shape is pretty much final. Not a flawless curve but it'll do for now. Since bondo loves pinholes there has been probably 5 priming/putty/sanding session so far.



Probably another coat after this, a fine sanding and on goes the white. The cable bumps will go on sometime also.



Front shell is a bit more of a problem. The front portion of it was just crappy and inconsistent so that got dremiled.



I knew it was slightly small and not far back enough, but it turned out to be 6cm too short overall. I ended up just cutting it up and gonna stack in some scrap 7mm clear acrylic sheets in there to lengthen it. Probably not gonna go the full 6cm, maybe just 3 layers sso 2.1cm.



At this point I was testing out how the front portion would fit so I temporarily super glued it on. Afterwards when I was prying it off with my knife the blade decided to slip into my left wrist. Missed everything important but now I have 2 stitches and only 1 useful hand for a few days with the portal gun needing to be finished by next weekend. I'm pretty sure I can still make it if I carefully plan it out and cut a few corners (less sanding time, not gonna be as perfect, no audio or flickering, just simple lights). This will be the ver0.9 portal gun for me. After next weekend's con I'll probably sand most of it down for near perfection and add the missing gimmicks.
 
Re: Portal Gun woes - Now an actual WIP thread with pics

Looking forward to see this finished! Hopefully with no more injuries- even if it is for science...
 
Re: Portal Gun woes - Now an actual WIP thread with pics

Looks awesome man! Great job on it!
 
Re: Portal Gun woes - Now an actual WIP thread with pics

Well, time to admit defeat for the 2nd time. There's just no way I'm finishing this for tomorrow even with all the corners cut.




3 hours before I have to leave for first day of the con
-No time to get the suit done
-No time to make the little wire bits around the claw bases
-No time to paint and assemble the claws
-White paint on the back shell is looking like arse
-Was gonna start on the body and front shell paint, but there's just no point now

I guess if didn't stab myself last saturday I might have finished with 2 extra working days but oh well. At least now I have 3 months to do it properly, with all the lights, sounds and other fancy stuff.
 
Re: Portal Gun woes - Now an actual WIP thread with pics

Too bad. :-(

You don't want to rush the paint, that's a mistake I made.
 
Re: Portal Gun woes - Now an actual WIP thread with pics

Thanks for posting those...

I LOVE this GAME..and was Blown away by V's Portal build and Im exciting to see TM's work here also.

its a project on my burner, with a TWIST. My 7 year old, wants a portal gun.

A "HER SIZE" version. Which means, I have to not only build one, but built a small one that will be destroyed 30 minutes after I hand it to her.

(sigh)
 
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