Saber Forum

I know building a prop or costume from scratch can be a intimidating idea, it does not have to be. With a little creativity, patience, basic tools and time you can make it happen. I will detail how I made my last custom blaster build from the initial idea to the finished product here. I do not have any major power tools, I use a ruler, box cutter, clamps, glue, B&D 18v hand drill and a pipe cutter. I also try to remain fluid through the build process, I allow the prop to help me decide on the final look as we go along. Sometimes I have a great idea and the prop decides to go a different direction. I have had my share of abandoned builds but no failures, I use the unfinished builds as learning tools to improve my next one. I have been in the middle of a build and lost the vibe, it happens, no big deal. Get rid of that one and wait until your inspired again, for me it's something I can not force to happen. I hope everyone enjoys this and gets inspired to try to make something.

Building props can definitely be an interesting exercise.
Been meaning to do a couple of 'from scratch' build myself

 Once you have a general idea of the item you want to build its time for research. This is a important time, its now when you can fine tune your plan. Do you want to make a exact replica or allow yourself to be creative and customize. For this one I decided to make a custom version. After spending time researching the DL-44 I decided to go with a carbine version, like the one seen in Solo. I found out that the DL-44 was popular in the Star Wars universe large in part to it being highly customizable.

Here are the pictures that caught my eye..

An original (non-modular C96 carbine)

(https://i.imgur.com/rxXvW71.jpg)


An modified (starwarsed) C96 carbine.

(https://i.imgur.com/Ou3lxk6.jpg?1)

A take on Beckett's carbine

(https://i.imgur.com/lgB9gUx.jpg)

Now the fun part starts, the actual build. For this one I wanted to really stretch my skills and only use what I had laying around from previous builds and in my greeblie bucket. I believe I only had to buy sandpaper, glue, washers,and blades. Because this was going to be a budget build I knew it would not turn out with all the minute details that would be present if I used a factory made gun as a starting point. I would have to make up for that during the build.

My first thrown together idea. I was still working out a general plan but I was liking it at this point.

(https://i.imgur.com/oO8ii6y.jpg)


This is the first glued together pieces, pvc tubing, strips of glued expanded pvc sheet (sintra), rubber grommets and a old BB gun scope.

(https://i.imgur.com/jAqYmb0.jpg)

I'm a fan of your work and collection

Now comes the "fun" part. Carving out and adding details, along with a few mistakes. In the long run the mistakes became welcome additions. I shortened the barrel, receiver and cut the trigger hole. I also added the scope mounting strips and trigger guard, along with positioning the scope and modifying the case. I made a few mistakes at this point but I was still early in the build and was able to fix them.

(https://i.imgur.com/Jh4f2oe.jpg)

Here is where I started to flesh out the core blaster, I added a handle and some minor greeblies to see how it felt. I did not like the trigger hole or overall profile.

(https://i.imgur.com/ponScJZ.jpg)

Here's where learning new things comes into play. I made a major mistake by cutting way too much away for the trigger. I used a piece of PVC and made an end-cap for it, filled it with epoxy and crossed my fingers. After cleaning it up and cutting it to shape ( I had never used epoxy in this way) I was satisfied with the filler plug and the overall look.

(https://i.imgur.com/YLV6nF9.jpg)

I decided to lengthen the receiver area and add a few more greeblies. This was a good place to stop and ponder the next steps, but it was beginning to resemble a DL-44

(https://i.imgur.com/7U5r56f.jpg)

Looking very good there.
May not be a DL-44, but definitely fits the SW look

Yea, I don't think I can call it a true DL-44, I just say its inspired by it.

After fixing the trigger area I had a few ugly gaps between the plug and body of the blaster. A little bit of creative use of sintra and volla it looks better.

(https://i.imgur.com/7U5r56f.jpg)


(https://i.imgur.com/xQjWGHe.jpg)


(https://i.imgur.com/QM8MI1U.jpg)


(https://i.imgur.com/xZZ9jXO.jpg)

I took a break from working on it for a few days and some changes became obvious to me. First of all the barrel was too long, a easy fix. Also I did not like the scope mount and I wanted to try something different with the barrel tip. I realized that the handle needed to be reinforced after it broke off falling from the coffee table. It was then I had the wonderful idea to take the build even further at this point and make it an modular carbine. I knew the handle would be under more stress then I had originally planned so back into my greeblie bucket I went. I found a metal sink rod and used it as reinforcement.

(https://i.imgur.com/8gGpUhR.jpg)


(https://i.imgur.com/S0EGUFZ.jpg)

AWESOME job it looks great!! Point to you.

Definitely looking good

I added some details to the barrel and removed most of the O rings, also added some grooves and detail to the receiver.  I changed up the greeblies and re attached the muzzle tip.


(https://i.imgur.com/I6cFnxi.jpg)


At this point I went ahead and primed and put the first basic coat of paint on. This is a great point to examine what the process has created and ponder any changes. The base coat of paint really helps to bring the whole blaster together. It mono color evens out the tone and allows some fine detail to expose itself.


(https://i.imgur.com/mgp8WTP.jpg)


(https://i.imgur.com/tE3lO8G.jpg)

I made a correction and filled in the curved part of the body of the blaster, It helped the overall lines immensely. Now it was time to take the shiny "toy" look away and start to give it texture and depth. A coat of Matte black paint and then black washing with acrylic paint adds the needed depth and starts to bring out the used feeling.

(https://i.imgur.com/Sn9Pf27.jpg)


A few more additions of color and texture really begin to make it pop. I have a desire to work more color into my props. I think that a black and silver blaster is just too meh.


(https://i.imgur.com/OXDDhYA.jpg)

Now I dive back into my Greeblie bucket and scrap parts. I dug up some PVC tubing, a couple of old plumbing fittings and a support from a old plastic shelf. Presto a drilled barrel housing and fittings. I forgot to take pictures during this step in the build but you can see it is pretty simple. The hardest part is mapping out and drilling the holes on the housing. Use many drill bits and slowly increase the size of the hole to avoid ripping the thin plastic of the shelf support.


(https://i.imgur.com/zrHYTVR.jpg)

[lots of pictures, with helpful text descriptions, NOT quoted to save space]

Wow.  This looks really good, and the along-the-way pictures and descriptions are really interesting, too.  Thank you for sharing!

I didn’t want to get too specific on in the individual step. But I wanted to walk people through what it takes to build a prop. And show them that it’s not really difficult just time consuming.

Definitely an interesting build to watch progress

One of the things that accompanies the build process is change. Great ideas do not always make great additions to a prop. For example I had planned this great hand guard gleaming with greeblies and hardware. Unfortunately when I started making the piece it really did not over all esthetic of the prop. I ended up throwing it away and starting over.


(https://i.imgur.com/LcE7WhO.jpg) 


I started out with rumminging through my greeblie bucket and made up a quick "sensor array". I painted and aged everything with the old tape method. While the paint still has not fully cured, but is dry to the touch, wrap masking or painters tape around the area to be aged and press firmly then pull it off quickly. The object is to rip off portions of the paint in a irregular fashion.


(https://i.imgur.com/4Ndo5SA.jpg)


(https://i.imgur.com/bhnCU6i.jpg)


(https://i.imgur.com/sE77zXH.jpg)


(https://i.imgur.com/qpOYlYR.jpg)

Nice project to follow! Love the pictures of the entire process.
Thanks for the tip of the weathering, will try to remember that one.
Point given.

When it came to the stock I debated between wood and sintra. I decided to go with sintra since I could give it more fine detail. I made the rough shape of the box with baffling inside to give it strength while keeping the weight down. I did not get a lot of pictures during this part of the build but it took me approx 10 hours to get it made and sanded/bondo.


(https://i.imgur.com/lrRi8ho.jpg)


A few greeblies and some paint and I am a happy builder.


(https://i.imgur.com/WnZlCtg.jpg)

Even at this late stage of the build I decided to make changes. I did not like the pistol barrel and decided to completely change it.

In the long run I am very happy with the final product. It is fully modular and very light weight, which is a major factor when trooping. I hope everyone has enjoyed this journey and either gets inspired to make something or at least is not afraid to step out and give it a shot.


(https://i.imgur.com/EQPebIp.jpg) 



(https://i.imgur.com/tSjM1xX.jpg)



(https://i.imgur.com/p0xfKgK.jpg)



(https://i.imgur.com/zUd2V5W.jpg)

Dry erase markers would also help to temporarily dissolve paint where you could wipe it before the alcohol in the markered area dries. It's also useful to fill in areas you can't mask off with tape that you don't want paint in, because it won't adhere to metals and plastics like a sharpie or permanent marker does.

Nice tip there, I’ll have to give that a shot.

Liking what you have here.
Keep up the excellent work

Beautiful work, love the ability of switching barrels.
Have to look up what sintra is. (First three seconds google translate didn't help)

It’s also called expanded pvc board

Thanks, I also had to look that one up, don't know if the hardwarestore here in the Netherlands has this. But I'm for sure going to look. Looks like an interesting material to work with.

It's a type of rigid expanded closed cell foam board. Cosplayers use it alot in making props, armor, etc. but it's also used in commercial uses for signage, wall board, etc. It can be easily cut with a knife, hand sanded, or with a dremel.