Build Log - Denix based DL-44

[Machinimax]

So as much as I love my original DL-44, I decided I'm ready to upgrade to something a little more realistic. Therefore, I'm currently working on a Denix based DL-44 blaster. (WOO-HOO!)

Now I'm no scottjua, but many of the design cues and ideas I have been implementing have been coming from his builds, so thank you for the inspiration Scott! Still I figured I would keep a build log for members to follow should they desire to try their hand at something like this. I want to install sounds and retain the functionality of the hammer.

Of course we will start with the Denix.



I cut off the tip off the very top of the barrel to allow the flash hider to slide on. I ordered the real wooden grip version but I think they sent me the synthetic one by accident....oh well. :P Here are all the greeblies.



I decided to go with the Luke variant. It's suppose to be my personal blaster but I figured it would also go well with my Graflex saber as well since it's ESB style. The flash hider, scope, and bracket are from Evolution Props and the motor greeblies are resin casts from a seller I found on Etsy.

I slid on the flash hider to see how it looks!



A little too lengthy for my tastes. I had to sand the barrel a bit so I could slide the hider further on. When it was done the flash hider fit like a glove. I LOVE the results!



The flash hider was then secured to the barrel by drilling and tapping a hole and installing a set screw. The folding sight had been secured with a dab of epoxy. Thus concluded the work needed done on the top half.



Next I worked on securing the bracket and scope. I drilled and tapped a hole for the screw and found a washer that is acting as a perfect spacer. I was even able to secure to nut on the inside and the washer allowed the tip of the screw to sit perfectly flush with it. I may have to remove the nut however to make proper room for the electronics.



Put it all together....



Basically done if it was a static prop (minus the motor greeblies). To finish up the outside, I need to grind off the Denix logo, drill the hole for the recharge port and aux switch, and touch up a few areas that lost some finish.

In terms of internals, this will play host to the Blaster Core v3 that was in my original DL-44. Since space is a VERY limiting factor, I needed I nice small battery pack. That's where a pair of 10440s came into play. Since they are not a very common pack, I had to wind up making one myself. This was actually a first for me but I was very pleased with my results!

[img]http://i1238.photobucket.com/albums/ff484/Machinimax05/DL-44%20Blaster/IMG_1941_zpsdylztkuy.jpg[/img

The internals require a bit more machining for wire clearance but so far so good. I even have a solution for mounting the switch. Put it this way...I <3 3D printers!! (One of the benefits of being an engineering teacher! )



So far, so good! I'll do my best to keep taking pictures and keeping you guys up to speed. Stay tuned and thanks!!

[Machinimax]

Time for a well deserved progress report!

The blocky and aesthetically unpleasing Denix logo (and text)....is no more!



Since I do not have a mill, I had to remove it by hand. I got rid of most of the text and logo using a grinding bit on my dremmel and then used a sanding bit to grind it closer. I wound up with a few gouges which didn't bother me at first since even Scott purposely leaves machining marks for realism. However, I decided to clean it up. I was back and forth between 400 grit sandpaper and steel wool. I was very happy with the results. Still a little pit or two but I feel that helps give it a bit of a used look.The metal then got re-finished.



Scott you are absolutely correct! That Birchwood Casey Aluminum Black matches the original finish PHENOMENALLY! I can barely tell the difference.

The motor greeblies have also been painted. I found a nice flat black spray paint for them. They haven't been secured to the blaster yet but I want to save that for the very end. Even though the Luke version only has one of the little hoop pieces, I'm going to use them both....just because I want to!



Up next, another Scottjua inspired move, the grip placed recharge port.



I've been waiting a week to do this part as I didn't have the right tap I needed and therefore had to order it. As you can see in the pic below, I milled a little bit of clearance. The port isn't flush but rather sits slightly recessed in the hole. It looks and feels great! You might also be able to see the little hole I made above the grip to allow wires to pass through to the main body.



Lastly, I machined down the wall separating the mag housing and switch area a bit to allow the wiring to pass through to the sound board.



Oh and I didn't take any pics of this but the inside of the grips have been modified a bit and now allow my 2W bass speaker to sit nicely within!

If all goes well, this should be all that's left:

- Drill sound holes
- Drill Aux switch hole
- Electronics installation
- Secure motor greeblies

More to come, my friends! Be ready!!

[Machinimax]

Cram. Fu. MANIA!!!!!



Probably my biggest cram-fu challenge to date! However, a few minor finishing touches left to go. Expect a glam thread and video pretty soon!