E11 blaster from scratch 2 week build

I’ve given myself a challenge !!!
on the 8th of May I will be 50 !!! Oh boy on the 12th of May my beautiful wife is throwing a SY-FY birthday party for me, she has bought me a .... ( cheap crappy storm trooper costume ) just for fun and far from accurate, so I thought I would dress it up ( ish ) as cheap as possible with an E11 blaster.

So here we go.
Day one, template down loaded,
With being a plumber I had some 1.1/2 inch waste pipe to hand (ABS solvent weld pipe) the type you glue all the joints together

I did a test cut and glued it back together as the OD was 42 mm and I wanted it as close to 38mm as possible

Knowing I could achieve the size I wanted I cut a 600mm length down one edge, I then glued the edge up and cable tied it back together

The glue goes off In minutes and totally hard for sanding in about 4 hours
once the glue had hardened I gave it a good sanding down, as you can see, hardly a seam noticeable
left pipe recut, right pipe as it was

Template down loaded and placed oround the pipe

I drilled all the holes and cut out all that needed to be cut out, I also cut, shaped and added the flash guard to the front and guard to the cartridge ejection point, the excess glue will be sanded away later

I thought I would try the T track to see how it’s looking

Ive also done some drawings on autocad for the muzzle pieces, hopefully they should be back tomorrow but I’m not holding my breath as my laser cousin can sometimes let me down.
So that’s where I’m at after day one more hopefully tomorrow

its time consuming looking for files and details and so on, if anybody has any info and willing to share, it would be greatly appreciated, it would also speed my time up on this build.

Question .... I’ve never painted ABS plastic before and after I’ve given it a sanding down it feels.... well I can only explain it as feeling oily !! I know its not oily, it’s dry as a bone but it’s just the feel of it, is there anything special I need to prime it with ?

thanks in advance and thanks for looking and reading

The muzzle pieces are done including a back piece for the barrel and hex bolts to screw up to, I will pick these up tonigh and try and put them together, I’m also going to try the front sight tonight

I forgot to mention on my party night depending if people are interested in what I’ve built this will be going forward as a prize for most original costume design ( the wife might win if this turns out to good to give away )

Just for fun, you created an awesome material. I really appreciate your creativity. Keep it up.

kerrymartin said:

Just for fun, you created an awesome material. I really appreciate your creativity. Keep it up.

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Many thanks

I’ve now got the muzzle pieces and I’ve slightly cleaned them up, they do need more refinement but they have the look I wanted, they are just loosely fitted


The back plate for the barrel and the muzzle has now been tapped out for the hex bolts and they fit perfectly

More cleaning up for the muzzle pieces and on with the front sight
tomorrow I will find something for the barrel, 9mm ally tube I think

Barrel sorted
11mm plastic pipe, 8mm copper tube, another back plate from the muzzle pieces for a spacer near the bolt end, knocking and banging a bit of glue and hey presto

Before the barrel can be fitted permanently I need to spray it up
now back on with the front sight


cleaned up and temp in place

Worked a little bit on my E11

i started with and waste pipe fitting and cut off one of the ends for the socket,
I flattened a piece of pipe, I softened it up in the oven then flattened it out, this was for an end cap on the socket, I did the flat piece 2 times to give it more thickness for shaping later

I cut some lines into the socket and pulled it together to give it a chamfered look, then filled the cuts for sanding tomorrow, it doesn’t look like much as yet, but it will ( hopefully)


With some more flat plastic I then started the front sight

I used a template and cut the shape required, back in the oven to soften up and bent it into shape, I also made the central pointer for the front sight and stuck it all on


I then started the firing bolt, I cut some smaller waste pipe, cut a 3mm channel out of one edge and glued it back to gether as I did with the barrel, this will now fit inside and hopefully slide back and forth when I put it all together

Drying now until tomorrow when I can sand it down and add some detail grooves

put some temp T track just for a look now the front sight is on

this where I’m at after day 3

tomorrow, working on the end cap, bolt, and hopefully the mag holder

Day 4
ive worked on the bolt, I sanded it down to fit inside the barrel, I also carved out the pattern that’s on the bolt, all I need to do is blank the end to receive the spring

I worked on the end cap, all I did was sand it down to the correct shape, I’ve a little more to do on this but I need to prime it to see if there’s any more sanding to do, I’ve also got to add a couple of more details.

I also worked on the mag holder
I printed off a template and cut it out, folded it into shape and tested it against my barrel

I then cut out the same shapes from my flat plastic pipe and glued it all together

The mag holder now needs to dry so I can sand it down and glue it to the side of the barrel


this is where I’m at at the end of day 4

Thanks for looking and reading

This is beautiful work. Your lines are immaculate! Definitely following this.

Buliwif said:

This is beautiful work. Your lines are immaculate! Definitely following this.

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Thanks
it was a last minute decision to build this I’ve only given myself 2 weeks to get this done, the more I do the more I see that still needs doing
I wouldn’t say immaculate lines, it’s pretty tough to get a neat edge bang on where it should be, a lot of sanding is involved, it’s not as accurate as it could be but I’m enjoying building it, I’ve always wanted one, but until I can afford to buy a deactivated one and convert it this will do

Thanks again

Ben

Just finished drawing up the folding stock to be cut from aluminium

Bed time now good night x

This is fantastic.
I love how it's all materials you had on hand.
This beats 3D printing any day, to me atleast.
Could you share what glue your using for the pipe?
Also, after you finish the stalk, I'd like to contact you about a few things about it.
Please keep the updates coming.
Robert

Bengrim09 said:

Just finished drawing up the folding stock to be cut from aluminium
View attachment 813815
Bed time now good night x

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That´s awesome...do you have access to a WATER or LASERcutter?

I need some small parts done in 1mm thick aluminium with pretty intricate details...maybe you could help me out?

OdiWan72 said:

That´s awesome...do you have access to a WATER or LASERcutter?

I need some small parts done in 1mm thick aluminium with pretty intricate details...maybe you could help me out?

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I do have access to a laser cutter but it all depend on the size and shape of your bits, I’ve tried to help kurtyboy out with some bits but only a small amount were successful, PM me what you have in mind or email me

I’ve had confirmation my bits have been cut, I can’t pick them up until this evening, mmmmm folding stock ( nice )

I don’t think it will be functional, only for the look, depends how difficult it will be to make it functional, time will tell

usajdm said:

This is fantastic.
I love how it's all materials you had on hand.
This beats 3D printing any day, to me atleast.
Could you share what glue your using for the pipe?
Also, after you finish the stalk, I'd like to contact you about a few things about it.
Please keep the updates coming.
Robert

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Thanks updates will be regular until it’s finished
This is the glue I’m using

Quick update, got home early from work so I thought I would have a quick play with the mag holder before the wife got home and before the chores need doing

A 10min sanding and double checking the bevelled edges to make sure it lined up and fit together nicely


I then glued all the edges and stuck it on, it’s now drying and all the excess glue will be smoothed away later

Tonight I will be having a go at bending the folding stock, I’m not sure if the sizes are correct as there are many different drawings and sizes out there, I will also be drawing up the handle and trigger section for cutting out of aluminium, top rail and anything else I can draw up

Not much done today mag holder done on the previous post earlier today

this evening I picked up the pieces for the folding stock, they are only 1mm Aluminium and a bit to flimsy, the files are for a fixed stock so it going to stay as a fixed stock

I’m having these re cut out of 1.2mm aluminium tomorrow

I then twisted some stiff wire around some 28mm copper tube to make a spring and plugged the end of the bolt for the spring to sit against

It will be able to cock back and spring forward, there was really no need for me to do this but I though why not

this is where I’m at, end of day 5
without T track


With T track


I don’t know what I will be working on tomorrow evening, I need to draw up the grip and trigger section, I might try the magazine and the Hen counter box

Has anybody got any decent measurements for the Hengsiler counter box ?

I want to make this tonight but I just can’t find what I’m looking for

Bengrim09 said:

Has anybody got and decent measurements for the Hengsiler counter box ?

I want to make this tonight but I just can’t find what I’m looking for

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Heres a couple that should help.
I believe credit for the pics go to Vern.
Robert