Jump to content

silverBoyd's DLT-19 build


Recommended Posts

The DLT-19...a blaster I've always wanted. Since it will be awhile since I can afford to do another full costume / armor, I figured I could build some Star Wars props / weapons. So far I have done a few weapons from the Star Wars universe: E-11 Hasbro modification (Hasbro mod's + Doopydoo's add-on kit....that I really like), Gaffi stick (from scratch), T-21 Heavy Repeating Blaster, a DL-44 Rubies (w/ slight mods and new paint job for my dad's TIE Pilot) and now a DLT-19 as a 3rd weapon for my Sandtrooper.
side-l_zpsc47f97e6.jpg

This is a work-in-progress so I'll add pics and "how-to" as I go on.

First, I started with a rough copy of the "Wizard of Flight" plans. From there I brought it into AutoCAD, re-scaled and sketched a new design. Slightly simpler but with detail.
1922705_10203203642435767_1307724317_n_z
I also sketched new template for the barrel holes as well as custom sketches for detail greeblies and parts.
10002784_10203296339193128_1774058655_n_

The proper width of the blaster can be achieved my utilizing (3) sections of 3/4" board glued and screwed together. I chose white pine. It's lightweight and also not too expensive. I transferred my custom templates, used my jigsaw and glued the together. I decided to attach the grip / trigger separately for various personal reasons.
1467190_10203257224575287_501147992_n_zp
72555_10203257517022598_872621600_n_zpsf
If you look closely at the above picture, you will see I made a "groove" in the center piece to "countersink" the grip / trigger. Once the wood glue set overnight, I sanded for about 2 hours to give the overall main body a nice finish and to round out and square off any uneven planes or edges. (2) 2" wood screws were sunk to make sure it was held together firmly. The screw holes and gaps were hit with some wood putty and sanded smooth. Turned out very smooth. I'm very pleased.
1896901_10203264340313176_1982198231_n_z

For some of my top and side greeblies, I'm using 1.5mm styrene (0.059" thick) (purchased @ local HobbytownUSA). I like the styrene because it's very thin and also gives great detail once the blaster is painted, finished and weathered. I also will use some Sintra (PVC board) that I have laying around for some of the barrel greeblies. The Sintra that I have is around 1/8" thickness.
4865BA65-DC4F-4839-8914-D8ADE4F3E4AA_zps
DD22BD22-7453-4C25-88B9-CA64791CDBA3_zps
(Attack of the Clamps)

Next, I began studying pics of the DLT-19. Upon looking at numerous angles I decided I want to "sculpt" the "big details" into the main body to get it as close to representing a scaled model of it. Here's the start of the body carving loosely based on the screen-used DLT-19.
IMG_6846_zpsfa91d226.jpg
834806B3-290D-429B-AEDC-3E082EB51DE2_zps
66FA9D2F-40E1-4DE5-9CD3-D4C60365CAB8_zps
9782ADE6-6252-4457-9977-D67958A65435_zps
651195C4-C9BF-4F8D-8FB4-86CE42CC34D0_zps
D5AC0617-AABE-4B6C-9590-0DA6DCC709AC_zps

Got a little more work done on the barrel. I am using 1" diameter (Schedule 40) PVC pipe for the main barrel and a small (4 1/2" length) 1 1/4" diameter (Schedule 40) PVC Pipe for the part of the barrel coming from the main body. I have "test fitted" these PVC pipes together via AutoCAD by being able to draw them in their actual nominal diameters which allowed me to check out how they all fit together due to their actual diameters and wall thicknesses. Should be nice when all said and done.
I also spent 15-20 minutes redesigning the "barrel hole" templates. Once i got the correct lengths cut out of the pipes, I taped the templates on and they fit very nicely. Just about perfect if I do say so. I start the holes by drilling out pilot holes with a 1/8" diameter drill bit. Lots holes. Pretty boring. Next I will go back and drill those 1/8" holes with a 3/8" diameter bit to give them their final sizes.
F0785835-42D6-47AD-A1C4-65667E846C1E_zps

I also began work on one of the PVC connectors that will be finished to resemble the barrel tip that has the flash hider on it. I see the DLT-19 has some sort of grooves. So...back to AutoCAD I went and designed a template for that based on measurements I took from the "Wizard of Flight" sketches. I used a small jewelers file to get them "carved" into the PVC connector.
CEA6CD4F-A61A-4C2A-B80F-7F414E8F29A4_zps
8A8238E5-5FD8-4D03-AD79-30E320D4A4D7_zps

I haven't started on this part yet, but I went to Walmart and picked up a $3.50 funnel. I went with the super tall and skinny type because it will give me a better shape for making the flash hider that goes on the tip of the barrel.
D109EAC2-1BBF-426F-B270-E261E0CF2DB1_zps

Spent an hour after work working on this thing. Having so much fun building it. It's really taking shape. Today I finally drilled out the 3/8" barrel holes and also did lots more sanding to the "stock" as well as sanded down more wood putty to cover up numerous dings and knocks in the wood body. Very nice and smooth. I also rounded a few edges that are rounded on the actual blaster. It's really starting to take shape.
A826371D-CA4E-488C-8504-00ADD59E883D_zps
(**NOTE** In the picture...the hole for the barrel doesn't look centered...but it is. It appears off-centered because part of that one side is carved away so it gives the appears of being off-center)
97535EE6-C100-47CD-B73E-E0BA6962F407_zps
Barrel's freshly drilled out..PVC connector pieces added just to give myself an early look at what it looks like. Templates I made are still attached.
A1800D7F-8870-496F-9FA7-248DF35D128B_zps
(Barrel not attached...just lying against the main body. I like the early incarnation of it. Beginning to work on scratch-made stationary bi-pod this week)

Started out as a busy work week for me (plus the wife being out of town so I had the kids alone for a few days). Finally had an hour after work tonight to get a greeblie made for the barrel. I scaled this piece from scratch via AutoCAD and transferred the template to 1/8" thick Sintra (PVC board). With my Dremel, a sanding wheel and a few various drill bit sizes, I was able to create this and test fit it to the middle of the barrel. It has a great fit. Here are some pics of the greeblie and the test fitting.
F3CD783F-71D4-4F10-B55B-CA59565D32C5_zps
E2B4657A-F24C-4734-8317-20C617805991_zps
6489E7A5-E648-4523-A706-BB1394E2E9D8_zps
F6109D8C-9F6D-4B66-B768-0E27E34BA959_zps
C2D76D4B-884D-4CA8-9470-3DC3350339AB_zps

spent 2 1/2 hours making more progress on the barrel...check it out

I am attaching a piece of 3/4" (schedule 40) PVC pipe into the main body and it sticks out enough for the 1" PVC (main barrel) to accept it via 3" or so. In order to make the 3/4" and 1" (schedule 40) pipes to connect, I had to use my Dremel and a sanding wheel to decrease the thickness of the outer diameter until it fit. It's not pretty but it's secure and will be even more secure once I apply some Medium ABS Cement. That stuff is used when fitting PVC together. It welds (melts) the PVC to each other. Awesome stuff. Once the 3/4" PVC was installed into main body of DLT-19, I added (2) screw thru the bottom of the main body to secure the piece.
78F93BBB-8F42-433E-861A-15FD34CB563D_zps
D98AFAED-5547-4FCA-A0D0-43CB099B19BA_zps
4E7A5FB3-0294-44C3-A38D-0ADF3C6D05D1_zps
F4318C89-0219-4C87-BDEC-0B89DD822618_zps
E6599EE3-B2B3-4355-AC11-8509AE1B9FF0_zps
167E1EE3-8537-49A4-9CC3-0B43C78DB234_zps
(Rough assembly)

Next I began the fabrication of my bipod. I'm making mine from scratch. I found a great metal shelf hanger @ Home Depot.
http://www.homedepot.com/p/ClosetMaid-12-in-Shelving-Support-Brackets-2-Pack-76606/100143993?N=5yc1vZc89l

I will be cutting off the "hooked" tips and hammering the ends out to be able to attach to a small 1" dowel rod piece
0EA659D8-3771-44B1-B04C-FBB0E7839F34_zps
E29CB4AA-C8F5-4DFB-B831-D0B5B443480B_zps
C34957B5-1FCB-4ACD-98D3-E38AF5A25F12_zps
E04C5EE5-1219-4570-BE67-F74B13E5DA0B_zps

Link to comment
Share on other sites

Had a busy day today...but managed to get a few details on the blaster. I was given a few small plastic pieces that I believe were from a hardhat. With a little work, I was able to make these pieces look like the "screws" or "bolts" that are on the real blaster.
06DF8EF1-3E6E-4E6E-96BC-30497F49883D_zps
609DFBDB-354C-46B7-8F5B-4D1BDCD0B97E_zps
4D72FAEF-426B-4BE8-98BD-B0F2F81D81A1_zps
E0C8C660-5C9A-4DA6-9A88-0F7D7EC85C68_zps

I was also able to crave out and sand smooth the "trigger". I wanted to give the illusion that there was a separate trigger on this blaster.
5665E497-94DC-45DF-BEBC-74A51AB3F50B_zps

I was able to get a small "greeblie" fabricated on the back of the main blaster body.

Here's an example of the piece I was trying to resemble on the DLT-19. I think I got it pretty close.
up-closeshot_zpsf89d4a1b.png

AD6B4EA4-8381-4779-AE78-253293D80EE4_zps
C5C13153-DD58-4FB4-87DD-E3D4E775B32D_zps

Link to comment
Share on other sites

Was searching for something to resemble some sort of bolt heads that are found on the DLT-19. After a trip to Hobby Lobby, I found a perfect solution. For $1.99 I found these great furniture plugs. Once i used a pair of needle-nose pliers and my Dremel, I was able to sand the nubs flat on the back and glue them to my greeblie using E6000. I'm pleased.
D0C1F6B3-EF27-47F3-A4ED-A30E380E54F9_zps
4270B672-38DE-4BCC-AD5D-1DF231D8FC51_zps
84963503-E206-452B-9CD5-B2F7EAF0ADC5_zps

Started fabricating my "charger box" for the left side of the main body. I didn't want to have to E6000 a bunch of styrene piece together to make the box so I came up with a template. I studing the size of the actual charger box and used those dimensions. In order to do so, I had to convert mm to inches. I decided to make mine out of a metal FOR SALE sign. It was the perfect type of aluminum and was easy enough to cut and bend into the right shape. I'm very happy with the end result. (NO FINGERS WERE HARMED IN THE MAKING OF THIS PIECE)
C252C4CA-949A-4A85-9A80-E5809774501F_zps
08D58486-0E88-451F-B9D5-9B76D73A9C97_zps
64E938F6-316B-4ED9-B4AB-D508ADC56B87_zps
9FB3B60A-8D28-4F43-8B5B-2A488E05C8DA_zps
19560DEF-5234-46CA-8DAC-99AAA91A18BC_zps
EF3B1355-A927-4890-8058-246855D3DE1A_zps

I tried getting the piece to hold via E6000 but it was a bust. My only solution to hold it together...good 'ole 1/8" rivets x 1/4" long. They worked perfect.
8A300EC8-30C9-4FD2-9263-7E621ED9DE90_zps
FF5AB367-6CA8-4947-8DEC-3F7A0D0A9E49_zps
C9E745C3-4914-4FFB-8453-2E0C82C67C62_zps

started my day by fabricating yet another greeblie. this one was an odd one that involved some carving (for detail). Not sure what this piece is though, but it sets on top of the "charger box". But I have it. I made this using scrap Styrene (1.5mm) and a little E6000.
F8D9B1A0-2B75-4247-813C-770D1E20FA62_zps
723F7D2C-B640-4D9F-B238-F359D6DD4837_zps
FDF67807-509D-4BA7-BF9A-B3F2E037AB56_zps
8235A0E0-12D4-4720-8430-7510F7282B16_zps

Link to comment
Share on other sites

Thanks...it's a fun build

worked on this thing quite a bit this weekend...lots of greeblie work as well as getting the bipod ready to fabricate.

Got the inner barrel cut to length, primed and painted black....not too exciting
9DF905D9-0ED9-444C-BF01-90074C3F32CF_zps

Mainly worked on the "right side" greeblies on the main body
2D825950-F2BC-4480-AED1-E8A5DE2F6253_zps
0FFFBD9C-4D04-4795-9F82-606E1B1D99C1_zps
F2C8038D-DB9C-464B-A46C-30EDB873EC45_zps
(TOP-DOWN VIEW)
ECE72151-DF96-41EE-BBE1-AEAEB5F91B3C_zps

I looked at pictures and tried to find the closest thing. The grip has (4) "bolts / rivets" of some sort. I mimicked this by finding typical flat pushpins. Using a cutting wheel & a grinding accessory on my Dremel, I was able to take off the pointed part of the pushpin. These turned out to be the perfect size. They are held on via E6000.

FA0FD7EF-52A0-445F-A90B-2A012EC85C84_zps
D3975566-66A9-4AE5-A762-9E2F69715032_zps
A4FA8F6C-ACD5-4512-8AA7-5ECDDDD90222_zps

Link to comment
Share on other sites

  • 2 weeks later...

Began work on the bipod (finally...after putting the barrel fabrication on hold for 2 weeks). I have to get this piece fabricated before I can get the barrel sections fastened together.

I started out with (2) 12" long support brackets from Home Depot. (Lowe's has these too).
http://www.homedepot.com/p/ClosetMaid-12-in-Shelving-Support-Brackets-2-Pack-76606/100143993?N=5yc1vZc89l
They resembled the bipod shape close enough. I could have opted for an airsoft bipod but I love building stuff from scratch.

After getting the 12" support brackets. Using a Dremel, remove the small hook ends (tabs). Cut an approximate 1 1/2" section out of each bracket, 1 1/8" from the curved end of each bracket tip that you cut off in the beginning.
0EA659D8-3771-44B1-B04C-FBB0E7839F34_zps
I used a hammer to make the edges as flat as possible. Cutting out a small slit on the sides will help you achieve making the ends flat.
E29CB4AA-C8F5-4DFB-B831-D0B5B443480B_zps
After drilling out some new 7/32" holes in the brackets to receive the machine screws I bought to hold it all together.
261DB746-579B-439E-8501-0BA3692C3758_zps
, I proceeded to cut out the 1 1/2" section from the total length. It is then fastened back together using an epoxy.
B6B99C81-0747-4CAC-AC49-C5887678B9E9_zps
E67044AF-1F37-4FA8-82F4-D5D109B8A879_zps

here's an updated dry-fit of the barrel on the main body
278ED5BC-3A00-4F00-85A3-463A87A346EC_zps

Last week, I also tracked down some T-Track from Georgia. It should arrive this week. Getting so close to being finished.

finish my bipod. I'm pleased. Not much to explain. You can see how it goes together from the pictures. Next thing I'll do before attaching to the underside of the barrel is trim down the bolt length now that the nuts are placed.
38511FDE-5931-4216-BE6D-9EA41A1F3C72_zps
A0E92FD0-1F70-4DF9-BB00-CE2F33851F27_zps
7F10A9B4-8880-475F-8D7E-2058105B1394_zps
8EB5F630-CA55-4EA4-A81B-1F4EAC66F1E2_zps

Painted this piece using enamel spray paint to give it a durable finish. Less chance it will chip off as much.
FE1DE74A-6EFD-451F-9712-990DF1D79D4A_zps
414E3C3C-A16C-4072-891A-FA02145484CE_zps
DF8355D1-05FC-4384-84B3-A92CB526F555_zps

Link to comment
Share on other sites

Not a lot of time to do much this evening, but I got the "flash hider" assembled to the barrel end-piece. I started out with a $3.50 funnel (tall and skinny type) because it will give me a better shape for making the flash hider from scratch.
D109EAC2-1BBF-426F-B270-E261E0CF2DB1_zps
Measured twice the depth that the funnel will insert into the barrel then marked and made a few cuts.
506C4749-76A5-4CAD-B2D9-7061CCC169B8_zps
The piece measures around a total length of 3 3/4" long. Only 2" of the funnel "flash hider" will actually be visible.
4E1B3760-EA92-4ED7-A3E3-B7B4316BD895_zps
I used Epoxy Resin (Gorilla Glue brand) to make sure it doesn't go anywhere in the future.

Link to comment
Share on other sites

Began installing the inner barrel. My inner barrel is a piece of 1/4" pipe made for water line installation. Very lightweight too. I wrapped duct tape around the bottom of the end that will be installed inside of the 3/4" diameter PVC pipe coming from the main body. I call this 3/4" PVC piece the "connector barrel". The duct tape wrapped around the 1/4" pipe gives it a nice snug fit inside the "connector barrel". I actually had to use a hammer to knock it into place. Even though the inner barrel is hardly visible, it gives it that extra depth of realism. I know it's there. That's all that matters, right?
4FECC1EF-38E8-441A-A934-A013A8D43999_zps
363AA6DB-6AF1-4DC8-8D1F-2325DBF0DFD0_zps
FCFB7DAB-F2D9-4EA8-BE0C-7CDCD280D9B1_zps
I will do the same thing to the inner barrel end that will be inside the "flash hider". No pics of it yet. Haven't gotten that far. The inner barrel has to be installed before the main outer barrel though.

Link to comment
Share on other sites

Here's a shot of the other end of the inner barrel that is inside of the "flash hider". The end is wrapped a little bit more w/ duct tape since it fits inside a 1" PVC piece rather than the other end which is inside of a 3/4" PVC piece.
8D8D92D2-70C2-4120-B2DB-80FB8AE2AEA9_zps

I measured the barrel sections to figure out the lengths needed for the T-Track. There are (12) T-Tracks total. Turns out I needed (6) @ 9 1/4" & (6) @ 5 1/4".
93F61000-C233-48F2-A08D-8372394B6DB2_zps
Before installing them, I used a utility knife to shape the ends of all of the tracks pieces. E6000 attached them to the barrel quite nicely.
75C2BB4E-4E00-484B-967F-E990A8477216_zps

The T-Tracks were installed following the pattern below.
79A9F21C-B384-416C-8BAC-00BED654A7B6_zps
1F4E5CCF-8875-4ACA-ADD5-F0F036A99E78_zps
33858E58-7D10-4EAA-A7DD-9D3F7A5DB361_zps
Once they were set and dried...I used a small cutting wheel on the Dremel to add notches to the ends of the T-Track. This is to help hold the wire that wraps around the barrel and tracks.
006D4EF9-9C37-42FF-8534-3C32A32E3290_zps

The wire used to wrap around the T-Track was found in the jewelry-making section of WalMart.
2BA9EA0F-3516-41E5-9C17-C9DC892CC5DD_zps
22D13C75-F3AC-40BD-BA6C-1F749BAEE915_zps
EACF306E-067E-4016-BB71-CCAB67DF3D16_zps
704CF9C4-D99F-42F7-B9F9-DFD519D2C537_zps
The wire was the perfect gauge and was easy to work with. After setting it around the T-Tracks I used needle-nose pliers to twist it and to clip the excess wire off.

Now that the build is completed..it's time for the final steps that really bring it all together. The paint / weathering process. I begin by adding (2) coats of grey primer.
F52886FA-F05E-47E8-B82B-384BA6F94E23_zps
16675934-7106-4848-85BD-F7EBF1B09BAB_zps
A844ADC4-008D-4E88-9670-468211A750F5_zps
C884D6B1-E8DC-46A3-ABD6-E0C96AD5B272_zps

Link to comment
Share on other sites

After 3 coats of semi-gloss paint were applied I finally attached the (stationary) bipod I assembled last week.

Started off by pre-drilling screw holes into the 1" dowel pieces that are part of the bipod assembly. I wanted to make sure that the dowels did not crack while attaching it to the DLT barrel. This part was very tricky since I was installing 1 3/4" wood screws around the bolts that connect the bipod together.
313DF5BE-5027-4D75-A40B-FBAD036DFE78_zps
F99D28F6-9C02-4FFC-8EF6-8264891FE11D_zps

After I pre-drilled holes in bipod attachment points, I gently laid the piece onto my barrel and lightly drilled pilot holes into the barrel. This way I could ensure that it fell exactly where I wanted it to.
47D2A528-93A6-4594-9381-49C7E52E4DEA_zps
75862D52-6A92-4E35-828F-0A6D1A4618A0_zps
Before I put the actual screws into position I added a small amount of E6000 for insurance.
A13770FA-1693-4819-9D62-C19E39EC737D_zps
BAC0C815-B3DD-4673-BF51-2F21DEE28554_zps
CF7582EE-A6E4-4698-8897-69BBF0AEA388_zps
I used a little of the spray paint on a Q-Tip to paint the screw heads.

Link to comment
Share on other sites

  • 3 weeks later...
  • 1 month later...
  • 4 weeks later...
  • 1 year later...
  • 10 months later...

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

 Share

×
×
  • Create New...