Only one real good reference picture of Kast`s rifle exists from the TEOD storyboard, and this is it:
So this rifle became my new project and my new obsession. So where to start with this....Well, the first step was finding the perfect gun base. So I went to Kay-Bee toys and found this:
Star Warriors gun
So now...time to get to work on it...
The first steps were to get rid of the top scope, front sight, and to cut out the bottom of the trigger guard. Also, I had to cut off sections of the top of the gun to house the "inside parts"seen in the original picture.
So after some bondo on the sides to strengthen it, and some more on the top to fill in some cracks, I`m good to go for the next step. Time to lengthen the barrel. Easily done with a piece of standard pvc sink pipe:
After this was done, I took another piece of PVC (smaller) and two pvc connector ends, and a singular circular piece of cut pvc to fashion the muzzel of the gun:
Drilled the vent holes evenly for the muzzel of the gun:
And then made the muzzel of the gun....all glued and ready to be applied to the master frame:
Now that the muzzel was done, it was inserted into the main frame of the gun. But before I could apply the very end of the gun, I had to apply a 1/3 cover cut from anothe pvc pipe and overlay it on top of the extended barrel:
Once this was done, I applied the flat sides of the blaster that I had cut from a rubbermaid trash can, sanded down, and applied "gun lines" to the front sides:
Once the main body was e and glued into place, I flipped the gun over and inserted a LOT of 2 part epoxy to strengthen the blaster and custom cut styrene squares to square off the bottom of the gun:
This is with the cut "squares " to fill in the bottom of the blaster:
At this point, I had to scratch build the ammo clip for the gun. I just used 2-part epoxy and smaller strips of styrene. This is what I came up with according to the reference picture:
And what it looked like once it was epoxied into place:
Once the clip was epoxied into place, I then could epoxy the muzzel of the gun into place:
Once the ammo clip was in place, I added the final pieces to the front muzzel of the blaster, then custom cut a piece of aluminum to the scope side of the gun to reinforce it for the weigt of the scope.
Once that was done, I added another flat piece of styrene to the top of the gun to be able to mount another one of the gun pieces seen in the original picture:
Now, once the top of the gun was ready, I was able to insert the custom made pieces into place according to the reference pic:
This is the piece I came up with. Just a couple of small pvc pieces, a metal hole plug, and a small metal piece from Home Depot:
And once it was painted and inserted into the top of the gun:
And now the second gun piece for the back top part of the gun:
The piece is made from a toothbrush holder and a metal washer for the front of it. Painted black and inserted onto the top of the gun:
Once the top pieces were complete, I could concentrate on making the scope. All the scope is 7 seperate pieces: A hose connector,a small pvc piece, a plastic washer, and a piece of 3/4 x12 PVC pipe cut with its ends off then cut down to size into 2 seperate pieces, and 2 cheap lenses. The first two pieces were a dead on match to the reference picture. They are a simple hose connector and a small pvc piece found at Home Depot:
I unscrewed the hose connector, sanded out the inside of the hose connector until the pvc piece would fit snug into it, inserted in the pvc piece, filled it in with epoxy to give it strength, and then screwed the piece back together so it looks like this:
The next piece was a piece of 3/4 x12 pvc pipe with both ends cut off,(I`m just showing one end cut off in the picture to show what it looks like both ways) then cut into 2 seperate pieces:
After cutting the second threaded end off of the pvc pipe, I measured both pieces to where I wanted them, to keep them consistant with the size in the reference picture. The ens measurements I wound up with are: The main body of the scope is
I first mounted the hose connector to the side of the gun with two small model screws:
Its a hose connector, 3 pieces of pvc and a metal washer with 2 lenses inserted at each end. The two screws held it at the hose connector, and once screw at the end of the scope:
Once the scope was in place, it was screwed down, the forward screw was concealed with square styrene. And the whole piece was painted:
Once the paint was drying, I tackled the front "second barrel" that sits underneath the main barrel. I just used another short pvc sink pipe, cut it down to scale, and expoxied it into place:
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