ZeroRoom

So here's a question for the team: Most templates have the rear sight as one piece and instruct you to bend it. However I have been doing some revision of the measurements for the rear sight, and for a variety of reasons mainly to do with the 2.5mm width of the substrate I don't believe this is actually possible to do and maintain accurate dimensions. The outer curve of the bend is simply too extreme. Witha gap width of 11mm at the base and a height of 15mm on the inside the rear sight has a total inner measurement of 41mm. However with a base width of 16mm and a an outside height of about 18mm the total outer measurement comes in at 52mm. This means 5mm in each curve which is a: very rounded and b: impossible to flat template out without ending up with an inner height that is too tall unless you cut a v groove into the substrate. Bearing in mind I can only examine photographs, it appears from my extensive research that the real Sterling rear sight was in fact two half circles not one bent shape. Can anyone confirm this? It's either that or a template with a large v groove which would not be easy for most folks to cut...

I'm pretty sure I know what it is - I'll get on it.

That's great Christian, thanks. Can you also double check the measurements on the template I uploaded for me? Particularly the parts around the 9 holes in the stock front - that was where I had to do most of my guess work. Meanwhile I'll apply those measurements. Congratulations on your upcoming wedding by the way! As someone who has done it himself I can highly recommend it No worries Mark - looks like Christians got the folding stock covered but I've still a few question marks on the tube template before it gets locked down. Will PM you the relevant bits. Thanks again both of you! This is really coming out great.

Don't stress Eric - its important that you keep us informed. Did this start yesterday or earlier?

Today's Update: The grip assembly - extra special thanks to MArk and Christian for this one. I've had to make some very small steps away from uber accuracy for this one. NONE OF THESE STEPS RELATE TO MEASUREMENTS OR SCALE. The things I've had to alter or improvise all have to do with the inner workings of the trigger/ grip assembly. I've created two kinds of inner grip. One that is solid and non functional, set to fit the non functional trigger template made earlier. The other is a hollow assembly, created for use with the accurate Sterling trigger template, however it does not include any parts related to a working trigger mechanism or genuine Sterling gears and mechanisms. The structure will allow for springs, electronics etc if the builder so desires, but no assembly instructions or measurements have been provided. I did this because firearms laws vary widely from locale to locale and there are many places in the world where making this part function is the first step to a firearms possession charge. The parts will look 100% accurate from the outside, even as a static prop, but anything more "accurate" will have to be the responsibility of the builder. We've all seen the Sterling Owners Manual PDF and you can refer to that if you want to risk building a working trigger. Anyway - legal disclaimers aside - here are the blueprints and templates: I've yet to add the plastic grip, because I'm having a hard time getting a handle (no pun intended) on how exactly to make a template for it being that it's so rounded and really needs sculpting. I will do something as close to accurate as I can but I'd probably recommend buying the outer grip and using it with these custom made parts. they are easily available and shouldn't cause import problems if purchased on their own. This site has them for sale for example: ------------ Boy - we're really getting there now!

Sorry - one more thing... Is the stock catch that attaches to the tube spring loaded or just a slide?

Oh yeah - just to confirm the little tube that mounts the folding stock BEHIND the trigger is 15mm OD yeah?

Fine drill bit (bout the same, tiny bit bigger, than the rivet stem) and drill right through. It'll pop right off.

@ Karin - Glad you're liking it! Thanks for the kind words and the 40mm A4 tube templates will be up soon @ Mark - no apology needed sir. We all saw what you've been up to in your b'day thread - and I've heard rumblings of an ewok uprising so your work does the empire a much needed service OK folks so here it is - the big kahuna - the folding stock template. Complete as one peice the way it was supposed to be: Now this one is the most tenuous of all as far the Lucas measuring system goes - I will definitely need double checking on this one. This is especially important since if we can lock it down right we should be able to make a template for a functional folding stock Which reminds me - can we post the OD of the tube inside the stock? Christians fantastic photos should do the rest, provided we can confirm or correct the measurements as listed here. Once this is done we will have a full exterior Sterling SMG template (I've done the rear sight I just haven't posted it, and I've almost finished the mag and mag housing). Then I can get to work on the insides... Here's the full scale PDF of the stock for those who want a closer examination or to do any edits (still an editable PDF) FoldingStockFull.pdf

Thanks so much Christian! That's a pretty crucial detail - I can't believe I missed it. I've added it to the tmplates, but I'm going to hold off on posting another change until Mark checks the other measurements - then I can go ahead and post confirmed accurate templates for 38mm and 40mm. Meanwhile can you help me out? I'm building the folding stock templates using your great pics and the other two threads with images of the stock. Would you call this measurement across the stock 15mm?: That's my eyeballed guess but I'd rather get a more accurate idea...

OK time for more questions as I go! Mark or Christian - we've clocked the diameter of the inner bolt at 33mm and the OD of the pipe at 38.1mm. Assuming the 'strips' on the side of the inner bolt are about 1mm thick does this mean the tube h a wall thickness of about 1.5mm?

Well guys, in the spirit of updating as I go here is the new template for the muzzle. I was quite surprised actually at how wrong the existing muzzle templates were. At first glance they seem to measure up, but closer inspection reveals otherwise. Mostly they were only off by a few mm - but hey this IS the best stirling templates ever project so we best correct it! The biggest thing is that no templates available include the dip here to accommodate the hex bolt that appears on a real stirling muzzle. So without further ado here are the accurate muzzle templates: And here's a question for everybody: If I take the muzzle dimensions and scale them up for a 40mm OD pipe I can do two things. If I scale the muzzle base up and leave the rest of the dimensions accurate it will look like this: If I scale the whole kit and caboodle to keep the dimensions relative, it will look like this: Which would 40mm pipe builders prefer? Back with more soon... and don't forget to chime in if you know something I don't!

I wished you a happy birthday over in the templates thread earlier if it helps! Now that the FISD is at almost 4000 members we've been discussing writing a hook to automate birthday messages, but haven't quite got there yet. No one has quite had the time as yet to do the old school 'and that's an order' style birthday messages manually every day yet. Believe me - I'm sure everybody wishes the man behind CFO a happy birthday!

Believe it or not that really is a Don Post helmet. He did some (slightly) better ones in the 90's with the release of the Sharper Image Stormtrooper statues but that's his original TK. I don't why he did them in rubber, but the same moulds were used I believe by Rubies for their rubber haloween trooper helmets. His Vader was in a nice shiny plastic (I've actually got one of those too, purchased at StarTours circa 1989/90) and it's not bad but boy is it small! Dave - if you're looking for info and history without getting headlong into then hobby side (I assume you're looking to turn this into something for BMX?) the check out www.StarWarsHelmets.com - they've even got the low down on Don Post!

Happy birthday sir! Hope it was awesome

OK - updated receiver tube template. I've corrected the 1/2 inch holes at the front that Christian cogently pointed out and placed the grip assembly using his measurements. I would still like some confirmations however before I go and lock down these plans onto printable A4's as well. With these dimensions I get a full receiver length INCLUDING the lug but EXCLUDING any part of the muzzle (even the sort of domed base of the muzzle) of 456.643 mm. Does this measure up Mark? Also I'm basing my stock mount, and therefor my trigger, on measurements taken from Sterling diagrams that I scaled to measurements I already know, so I may be a bit off. Can we confirm the lug to rear stock mount measurement? Again here's a preview image for those who just want a quick look with the full PDF attached below: Tube38mm.pdf

This is great! I love how every submission to this topic just keeps raising the bar.

Karin - I will indeed make A4 templates in both sizes. We all use A4 except for our US brethren who will need US Letter. Christian - Good spot. As to the grip I was hesitant to place it with no measurements. I know it butts up against the rear stock mount but some proper measurements would be great!

Yes indeed Vern - Mark included both measurements and they've been taken in to account. So... the moment we've all been waiting for - the first draft of the adjusted 38.1mm receiver tube template. These are the changes I've made based on measurements supplied by Mark, other topics here on FISD and net research: Correctly and evenly spaced vent holes Corrected rear sight size for placement guide Corrected stock clip size and placement Corrected Cocking Slot Length Corrected Ejector Port Length Corrected Ejector Port Placement Corrected Folding Stock Rear Mount placement and size Corrected Mag housing placement guide size and placement Corrected Front sight size and placement This is a preview jpg of the result: In the interest of better work I've also attached the PDF file at the bottom of this post so people can download it and double check stuff. I've saved it as a PDF so it's readable by all and maintains it's proper scale, but I've saved with "Preserve Illustrator Editing Capabilities" intact, effectively making it an 'open source' file that anyone can edit or correct if needed. If you do edit it though be sure to post it back here for all our benefit and detail your changes! Next up I will post the version for a 40mm tube after adjustments. PDF: Tube38mm.pdf

Hit the little switch in the top left corner: That will give you code view if you want to copy and paste or alter any code you are editing or quoting.

Excellent - I know this is a tiny change but with a few tweaks it will make all the difference. Getting there now - getting there.

OK Team - so this is the issue I'm having I was talking about last night. I am looking at the tube template (the whole reason we started this malarchy in the first place) and I need to clarify some measurements. These measurements have been covered in this thread by Sonnenschein here: http://whitearmor.net/forum/index.php?showtopic=15773 However there is something off about these measurements and they don't add up. Here is a quick demo of the measurements I'm talking about, I've made each one a different color so they're easier to differentiate. According to the afore mentioned post the measurements are as follows: A - The distance between the end of cocking slot and the end cap: 8.75mm B - The length of the cocking slot: 163mm C - The distance to the furthest point of the ejector port back to end cap: 183mm D- The distance from the closest point of the ejector port back to end cap: 171mm E- I've added this one in hopes I can check the template accuracy just using the total length between furthest dots and letting the computer do the rest. The distance between the end of the cocking slot and the end cap, and the length of the cocking slot seem to add up just fine. It's C and D that are causig me problems. They push the ejector port way too far forward, so that the closest point at the ejector port back is still a good centimetre or more away from the cocking slot, not just underneath it like it should be. So in short could we check or correct these distance? It wouldn't take long at all to do the tube templates if I had this. (Info on exact grip placement might come in handy too....) Sheesh - I never thought I'd use the phrase "cocking slot" so many times in one go....

Dude - you've been massively helpful you've posted so many helpful pics it's amazing. We all owe you thanks, but fear not I'll still come knocking with more questions

Thanks Mark - you're unstoppable! Trigger set up and those damn blowback shields: (Now I know why they're not included in any of the usual templates)

OK Further updates, further information requests. I spent forever trying to get the blowback shield curves right with a template that will both curve in the crescent shape while also wrapping around the diameter of the pipe. After many hours and some very patient and valuable help from my wife (she drafts patterns for a living) I do believe I've finally succeeded. I'll post the results tomorrow, as I'm posting this from bed and I'm half asleep, but a few questions have arisen meanwhile. Looking at this image again: The total length of the bolt appears to be 140mm. However using your 123mm x 7mm measurements for the side strips Mark, I cannot for the life of me get the strips to run the length of the bolt (as they do in the pic) at ANY angle. Am I reading Christians photo wrong? Actually I'll leave the other questions til tomorrow... They really require drawings....