the kit I got was chopped this way
Even getting alu tubes in the UK shipped to me wasn't that easy, since it's heavy and not all vendors will accept to ship across the channel :unsure Also, with the humble machining tools I have, alu remained the easiest solution.
here's some more of the build log. I wanted to have the blaster Powder Coated cause I like props you can hang around with, without the fear of paint chipping and so forth.
2 stressful days cause I was SO afraid to miss the PC job. I first went to buy some oxalic acid (you guys call that Naval Jelly, rust dissolver) to prep things nicely. I also baked the folding stock and the main body since I noticed it helped neutralizing the rest of paints, oil and so forth.
Baking also gave the final kick to the steel epoxy on the main body, which stabilized and didn't melt at all.
Then I cleaned with water, then with biodegradable degreaser, and wiped properly, then compressed air to blow away any trace of moisture.
I resisted to the envy to re coat the folding stock (an area isn't thick enough) but I didn't. Too risky.
First, I remembered about the faraday effect during the PC job, and I was worried about not having the inside of the barrel dark enough. So I protected the beast and PCed the inside with a light mist of flat black (then I hadn't made more experiments with the satin black I had and I didn't want to ruin anything).
then after experimenting the right flow out time and temp on a scrap part,
I played again with the satin black on the trigger and its guard. I learned there how to (almost) fully disassemble a trigger group, which helped for cleaning it from all the grease.
PCing the folding stock. First stress of the day
final results once I've baked all the parts (the oven heated the whole afternoon, I couldn't stop). I also made my scope rail.
Still a light texture but that's exactly what I wanted
You can see the difference in the texture of the butt cap. It's not just due to the primer coat of flat black, the surface of the metal was different.
Stock locks (and 2 smoking barrels :lol)
the shorten magazine
with a nice decorative inserts (SO-dim 1GB... well that's only 512 MB now :rolleyes - They didn't want it back at work after I upgraded on my previous machine)
Getting close. Received my uber accurate T-tracks from Gino yesterday. Strong ABS extruded plastic with the right gaussian profile.
Grinding the bolt. Why ? because it's hiding something (see below). Taking a picture while actually grinding isn't easy when you have only 2 hands and no tripod and when you're tired to make efforts... (I know, use the Force to levitate the camera)
wiring the satellite board on the barrel. After checking between having it right next to the Blaster Core board or here, it was easier like that, less wires and an easy power supply split for the barrel end flash RGB led. The latter has its power xtender and resistors all local, and protected with heatshrink. Once glued, the LEDs were covered with some masking liquid (latex from what I smell... brand is Maskol by Humbrol), then I painted the whole barrel with some regular satin paint. It's weird to work again with spray paint once you've done some powder coating. Takes ages to dry (impatient me), chips and marks easily buy since it's going INSIDE the body of the E11 so I don't mind.
A big part. A crystal chamber. I wanted to have (among other things) some glams for that projects. Also, the bolt is visually such a nice piece of mechanics that I refused to do a static thing with it, with a piece of chrome tape. So you can still xxx the bolt and it moves back to reveal some (simple) internals. I mounted an aqua aura crystal on a small ring/mount JBwelded to the bolt and it goes straight in the barrel.
The internals were assembled on a thin copper plate (polished a bit), the thin comb of brass/gold is an old SD card reader that came with my previous laptop, as well as the control card (sanded, and glued). You can also spot 2 anakin brass pins, a weirdly shaped coil from a hard drive and a few other bits I had in my drawers.
Once everything was installed, I placed a small headless screw behind the handle to stop the bolt from going back too far (and smashing the wires going in the handle, to the trigger group). It's not moving back a lot, but it's enough to reveal the internals. No led there and no reason you'll have any, getting the bolt back disables the weapon. Initially, I was supposed to use the bolt as a range selector / unjamming operation but I didn't have the right spot to place the sensor/switch and I consider the bolt and wires just behind it too fragile for using that on a standard base.
Installing the electronics in the back. It's one of the most difficult wiring job I ever had to do (my yoda saber retrofit was easy in comparison). Not only there are a LOT of wires but they have to extend to allow servicing the board if need and they have to fold properly when the chassis (PVC) is inserted in the body of the sterling. Add then that you have the functional spring and the bolt that still have to move freely without smashing the wires.
Also, fourteen (14 !) wires are going to the henglser counter. Holy cow. I used some of my 30 AWG ribbon cable. It's a solid wire in there (no strand) but that was my only choice.
The trigger group. No limit switches, but Hall effect sensors and small neodymium magnets (3mm OD) and secured with activated (spray) cyanoacrylate glue. They act as a switch when the magnet is close enough. Inside, it's actually an open drain MOSFET transistor, just like a power xtender board.
The only switch I used is for the AUX switch (range / reload). I'm going to cut the screw that secure the trigger group to the handle and body and the rounded end (the one not having the screw driver slot) will be attached to the switch plunger (removable). On the other side of the handle, where you read the "Free / Lock", the other half of the screw will go on a M3 head less screw that installed on a small bolt then glued on the back of the aux switch with some JBweld. Original Look will be preserved.
more to come, I've taken about 110 pics during that build log :o