Hoth Han DL44 - a Denix Story..

grimsheeper · Jan 26, 2018

This is my first RPF build thread.. so let's see how this goes. I am currently putting together an "as accurate as humanly possible" Hoth Han solo. Snow and all!

My blog for my build will be on Blogger : https://hoththerecord.blogspot.co.uk/ This will have the full size photos..

So i've been reading thread after thread on here and then managed to find some UK Suppliers of Denix's. I managed to find out if they were the "v2" and ordered 2 (one for a friend).

I was pleasantly suprised when it arrived. There are noticeably better upgrades/fixes on this from the v1.

No Denix Diamond logo
Plastic grips (downgrade!)
No cartridge refill guide cutouts
Sight slider was solid and single piece
Curve between trigger guard and grip much more curved
Less pitting/Better quality

Here is is out of the box

Notice in this pic i started to scrape away at the "paint" on the magazine.. wasn't happy with that! So i went about poking at it and the file came out.. and the sandpaper... oops!

Started to sand down the obvious... but you know what this leads to..

Started to file and sand down the pins. Used 150 grit sandpaper and followed up with 600 grit W&D for the final finish. I have done this for the whole gun so far but used 1200 when getting a final finish.

This was the first attempt using the dremel. Its scary, it shreded the metal and took ages to sand. I will be more careful with it from now on. After some sanding its smooth again... but be warned!

Filed down the firing pin to more of a nub

grimsheeper · Jan 26, 2018

Day 2

Detailing the "seam" for the clip

Its really hard to do this bit! Tip - score first - file later!

These annoying pin holes will need filling and sanding later...

Its all getting filed and sanded now.. every little groove i can get to (man this hurts your hands)

This will be filled and sanded later..

Barrel sanding starting... This is now 600 then 1200 grit sanded.. its smooth as anything now!

Next up, those pesky little washers that need not be there. This is about 10 mins work with a hand file, then sanded.

Whilst I was there I started to pick out the scope lettering.. really tricky and fiddly so take your time. Its very easy to fly off and scratch the rest..

grimsheeper · Jan 26, 2018

My Epoxy weld turned up from Ebay.. so got started. (Damn that stuff dries SOLID!)

"M96" logo filled in and later sanded. You have to leave it at least an hour but as there's not much it dries quickly. In retrospectI would say squash it in the gaps ASAP and leave it overnight for best results.

Pin hole above Trigger filled. This is after sanding.. its so smooth now you wont tell its there once painted/blued/weathered..

Started to re-shape the trigger but hand filing this was a b***h. So I am going to try dremelling it tomorrow. I figured as its a curved piece the dremel might tackle this quite well

Glued a washer on the bottom and started to score around it for my cartridge seam

I was really tired and accidently started scoring the wrong side at one point!!! DOH! Not that it matters i'll sand it off later..

Started re-shaping the firing hammer. This is not yet complete but looks loads better already....

Re-filed the knurling on the hammer too... this looks and feels so much better now!

KramStaar · Jan 26, 2018

Looking good.
If you replace the pins with longer ones and then file them back flush with the body, they practically vanish when everything is either blued or painted.

Best of luck.

MARK

H0llyw00d · Jan 26, 2018

KramStaar said:
Looking good.
If you replace the pins with longer ones and then file them back flush with the body, they practically vanish when everything is either blued or painted.

Best of luck.

MARK

This. Then when you decide to do a sound and light install you aren't kicking yourself.

Not sure I'm sold on the v2 Denix. So no diamond and funky burr on the left side. The trigger looks off... not sure I'm seeing the benefit. Plus the whole "made by denix" business on the left side... Meh... :/

grimsheeper · Jan 27, 2018

I think it's better overall [emoji4]

I am not planning on doing a sound/light install in this one. Mauve the next one. In the UK garrison/Rebel Legion there's a lot more focus on accuracy and canon then cosplay fun. You would get less respect here if the gun actually pew pew pews.....

The trigger will look better when I've finished it.. the me by Denix was easily filed away so no issues there

grimsheeper · Jan 27, 2018

KramStaar said:
Looking good.
If you replace the pins with longer ones and then file them back flush with the body, they practically vanish when everything is either blued or painted.

Best of luck.

MARK

Thanks for your reply.. I'm enjoying this so far as it's my first Denix it DL44 build ever. I will do that next time just so that they are metal.. it wouldn't be too hard to drill the epoxy out if I really really wanted to

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matty matt · Jan 27, 2018

Nice work!

grimsheeper · Jan 27, 2018

matty matt said:
Nice work!

Thanks Matt. As everyone I'm sure, I'm also following your inspirational guide and tweaks. My hands are killing me..

Progress today :

Completely reshaped trigger and sanded smooth. Finished (ish) magazine seam.. this metal has a tough grain and of you go against it you get jagged edges that I just couldn't reshape... But I'm still working on it.

Release button hole drilled and plastic release button added. I'll add a metal one when I find something better.

Reshaped hammer to look like original. I have a weapons book with original photos in to copy. I also saw that the release button centre lined up with the magazine seam lines centrally so moved mine back a bit. It's not quite central of I'm honest but no one what will know once it's all painted and weathered...

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thd9791 · Jan 27, 2018

it depends on the Denix, but You could try to find MGC grips to fit, since the original was an MGC. Mine are the red 9s with the number filled in. I had to resculpt the inside of the grips but it made it look very different.

Anakin Starkiller · Jan 27, 2018

Do you already have a flash hider? I have a couple left from my last run. They're the most accurate available

grimsheeper · Jan 27, 2018

Anakin Starkiller said:
Do you already have a flash hider? I have a couple left from my last run. They're the most accurate available

I do not! And I do need 2....

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mencodave · Feb 5, 2018

looking good. alot of work goes into this build and from the pics you are sure putting it in. cant wait to see more pics

grimsheeper · Feb 5, 2018

mencodave said:
looking good. alot of work goes into this build and from the pics you are sure putting it in. cant wait to see more pics

Thanks.. I have a lot more to upload later!

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grimsheeper · Feb 19, 2018

So I have done loads more work so far!

The blaster has been 'blacked'

After a few coats and being left for 10 mins this happens :

Then rub it down with a little gun oil or something and a rag, and it changes completely.

So it's coming along!

grimsheeper · Feb 19, 2018

Removed the sight!

Firstly sawed it off

Then sanded :

- - - Updated - - -

And today these parts have arrived !!!

The quality of these parts is amazing

zjunlimited · Feb 19, 2018

Nice!! Keep up the good work

grimsheeper · Feb 20, 2018

Anyone have a specific guide for the placement of the scope/mount?

grimsheeper · Feb 24, 2018

Ok so I found my own info and have finally finished it!

There has been much spraying and weathering done today. I learnt the method of using petroleum jelly.. I am really pleased with the outcome.

The last few days I have :

- Drilled holes for scope mount (massive pain doing this). Note that the metal scope/bracket kit comes with US imperial thread and UK metric doesnt fit
- Bought new M2.5 bolts in the UK with metric thread
- Drew lines on flash hider with Sharpie
- FH given dusting of black then all sealed in with clear lacquer. Worth noting that clear lacquer made the sharpie run and its thickened out the lines.
- Sprayed parts and weathered. Used the method with petroleum jelly in multiple layers. Scope mount was sprayed bronze first then revealed with this techique. Scope mount was sprayed silver first, and disc was sprayed bronze, then silver, then all parts had top coat of black
- painted over small parts which wered blueing (metal weld/Epoxy parts)

This was the goal :

And this is my final product!

grimsheeper · Feb 24, 2018

Though i've just done an overlay and noticed teh barrel is a lot shorter in the original.. guess i'll be chopping that down tomorrow!

Hoth Han DL44 - a Denix Story..

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