silverBoyd's DLT-19 build

[silverBoyd[501st]]

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.

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.

I also sketched new template for the barrel holes as well as custom sketches for detail greeblies and parts.


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.


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.


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.


(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. I'm going for detail but not going for 100% accurate. That would be very hard without have an actual cast or vac-formed blaster. Here's the start of the body carving loosely based on the screen-used DLT-19.







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.


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.



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.


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.

(**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)

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.

(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.






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.






(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

Edited April 6, 2014 by silverBoyd

[gazmosis[501st]]

Love your mods so far!!!!

[TK bondservnt[501st]]

ding ding... we have a winner! 

 

nice thread...