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budget Luke's DL-44 Bespin Blaster

 
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Schph Gochi (Phyllis Schulte)
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PostPosted: Thu Dec 13, 2012 11:23 am    Post subject: budget Luke's DL-44 Bespin Blaster Reply with quote

When asked by a fellow Base mate to help with a Bespin Luke costume - mainly in the area of the holster, belt, and blaster, I started to do some research as to what was available.

According to "Parts of Star Wars"
they are talking about the Han Solo weapon here:

"This prop was made from a replica German "Broomhandle" Mauser pistol manufactured by the Model Gun Corporation of Japan. This blaster is nearly identical to the DL-44 carried by Luke Skywalker.

Though it's long been believed that Han and Luke had very different muzzles, they were actually nearly identical- both had 3 knurled bands around the collar. The reason Han's seems different is because it was made much rougher and the knurled bands are misaligned and run close together in spots.

The scope mounted on the side is either a M19 or M32 brass azimuth telescope used by the military in many applications including tank periscopes. These were made in 1942 by Minneapolis Honeywell Regulator Co. (M.H.R.). We believe the M19 is the more likely scope used and it was attached with the original hex head bolts."



Most everything was very expensive so I set out to do a blaster for about $100.00.

After looking around, this is what I made.

I started with one of these that I picked up on e-bay for about a dollar (less than $15.00 shipped)



Then I started to look around for flash suppressors and scopes and decided that the best way to get everything else I needed was to purchase a Doopydoos Han Solo ESB Blaster:

http://www.doopydoos.com/star-wars-replica-han-solo-esb-dl-44-blaster-prop-kit-2690-p.asp



Here is a photo comparison of a metal Denix replica, my custom blaster made from a metal Denix and the airsoft from E-bay






The airsoft is nearly identical in size to the un-altered Denix
...
but is slightly different:





By combining the Airsoft and the Doopeydoo
I will still have a trigger that works...
a hammer that moves
and
I think it will end up with more crisp detail...










The flash supressor is solid....so that can be cut off the Doopey Doo and drilled out and put over the Airsoft as the barrel on the airsoft is removable to just about the right spot...


sanded off the "made in China"
and filled in the markings on both sides...they were "carved in" rather than raised letters





I then cut the flash suppressor off of the Doopeydoo
drilled it out
and dry fit on the Airsoft







here are some photos of the flash suppressor done in rub and buff...I included the packaging of the product so that you could see the label....I bought mine at Michaels...


first I sprayed the piece with black because I wanted some of the crevaces to be black with dirt and age...

I intentionally did not apply it on thick because I wanted that black to show through some of the areas..
I also applied smoothly on some parts..
and stippled on other parts...just for "age"...

I can always go back and add more...but I rather like its "beat up" look as it is...so I think I will leave it alone...








One thing I wanted to do was to make the mods to the Airsoft BUT leave it fully operational...
so..
I took the scope mount





and sanded off that raised disc.....so that the scope mount could be glued right to the airsoft.....I didn't think attaching the scope mount by glueing just that small round disc would hold well enough.....I didn't want to drill and screw into the ammo clip.





Scope mount attached:







Since I removed that disc...which is a spacer....
I had to sand off some material off of the mount at the base of the scope to compensate a bit...





I also drilled out the flash suppressor so the BB's would go through it..




Scope glued and mounted...






I did end up drilling up through the bottom of the scope mount and into the two "feet" of the scope and adding small screws to just add a little "insurance" that the scope stayed on the mount. We all know that trooping can be hard on stuff and sometimes glue fails.


I decided I didn't like the too new and too shiny grip...

so...
I mixed some black acrylic paint with water and brushed it on
left it just a bit
then wiped it off ....it left paint in the grooves and toned down the color a bit...


before:




and

after:






and....
stick a fork in it...
it's done...

Not happy with the paint...but decided to give it a rest...

first I painted it flat black...
then I added some "weathering"...
didn't like the weathering so I sanded most of it back off..
painted it flat black again...
decided I didn't like that and put a coat of satin clear over it..

decided I didn't like that and put a coat of flat clear on it...

still don't like it...
but...
not sure what I want to do with it...
so I am leaving it alone for now...
I may go back to flat black....


and...
yes....it still fires....
I loaded it up with BB's and was shooting at my front door....
lol....
there were BB's richocheting all over the place..

Very Happy














Not saying this project was perfect, but I think it looks ok for about $100.00.

Now...
on to the holster....
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Havok69 ()
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PostPosted: Thu Dec 13, 2012 2:10 pm    Post subject: Reply with quote

Looks great! I'm not a fan of all the inaccuracies of the airsoft, but you took it to a new level and made it look much better. I love that it still shoots. Now you just need to take it to the next "Shoot a Trooper" event...

Mr. Green
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PostPosted: Tue Jan 08, 2013 12:57 pm    Post subject: Reply with quote

yeah, I reckon that's pretty cool actually !
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Schph Gochi (Phyllis Schulte)
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PostPosted: Tue Jan 08, 2013 3:33 pm    Post subject: Reply with quote

I started on the holster for it...







long way to go on that....
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SithariRog (Roger Allen)
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PostPosted: Tue Jan 08, 2013 6:01 pm    Post subject: Reply with quote

An awesome tutorial.

Mind if I cut and past this post into a PowerPoint and use is as part of my Star Wars Prop Making panel at Connooga March 2nd?
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Schph Gochi (Phyllis Schulte)
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PostPosted: Tue Jan 08, 2013 6:10 pm    Post subject: Reply with quote

SithariRog wrote:
An awesome tutorial.

Mind if I cut and past this post into a PowerPoint and use is as part of my Star Wars Prop Making panel at Connooga March 2nd?



feel free...

Very Happy
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Schph Gochi (Phyllis Schulte)
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PostPosted: Mon Feb 04, 2013 1:25 pm    Post subject: Reply with quote

I finished dying and stitching up the second Luke Bespin holster...this one turned out better than the prototype as I learned a few things making the first one....as is always the case...

also..the stitches might be a bit far apart on this one...I had them way too close on the prototype...so I need to hit a happy medium on stitch length..
this is only the second holster I have ever made...so...not too bad...



































backside...
I did it like this to keep things from moving around




and


voila'











Next up is that round pouch that Luke has on his belt...

I started out by trying to figure out how big this piece is supposed to be. I was not able to get a pattern or a size....so..
I winged it...


I cut one piece of 5/6 oz leather for the curved part (not sure that was a good idea) and a 7/8 oz for the back panel


next I soaked the pieces I cut in warm water for about a half hour and then wet formed the thinner leather piece over a piece of pvc and left it to dry....I actually let it dry for several days cuz I was busy and could not get back to it.




that is an old wood cutting board I am letting it dry on..




After dry...
I got this..



I had to cut the fold over part of the backing piece so that it had a curve...



and...since that leather is pretty thick I decided to skive the backside of that flap to make it more flexible...






After that was done...
I checked the fit



It is here that I began to argue with myself as to whether or not to dye the pieces first.....or to assemble and then dye...
I decided to assemble and then dye...

Next I had to address closing up the bottom...
didn't really know how to do that so...
I traced the opening at the bottom and made a template



then used the template to cut out a piece of leather...
and checked that fit





it fits "meh" but not too bad....

Next I had to mark and punch holes to stitch that piece in...
never have tried curved pieces....so the adventure began...

I used these little wheel thingies that Bob Kohn showed me...they come in a couple different sizes....





Utilizing Bob's procedure of punching every other hole...I chose my smallest wheel....and very carefully ran the wheel around the curved part of the bottom piece first
and then the bottom of the wet formed piece...



Next was to actually punch the holes...
I used an awl that I have various sized "blades" for...






and punched the holes in the bottom piece



For the record...
I have tried using one of these to stitch...and...well...
didn't really love it..
so I just used regular leather needles...




Well...
trying a curved needle...
broke the first one...but had a second one...




I can tell already that this will not go well...



No matter how I prepped and counted...somehow or another...the holes for this base part are off kilter



but...
onward and upward...
back to a straight needle to do the sides...





after stiching I used a little Barge cement on parts of the seams



Preparing for the snap at the top






Snap set



First coat of stain on...looks cr*ppy....
hopefully the second coat will make the piece look better






Will let the piece dry overnight before the second coat of stain

ok...
last coats of stain are on the piece...
still does not look really good...still blotchy...




and this is the pouch with the blaster and holster:



The round pouch came out rather terrible. Usually I come away from a first attempt/prototype with solid ideas on how to make it better....this time...
I got nothin....


Hopefully this information will help someone..

I am NOT a leatherworker and only dabble...
I have only the most basic of tools...
yet I have been able to turn out something presentable...

my advice to all
is to try

Wink

next up is some of the other pouches.....and the belt..
.but I have other projects I am working on so it is likely I will not return to this project for awhile....
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_Master_Skywalker_ ()
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PostPosted: Sun Feb 10, 2013 1:19 pm    Post subject: Reply with quote

yeah sure you're not a leather worker !!

That looks REALLY great Phyllis !!! Razz

I love that blaster Phyllis. If you ever made another....just sayin ' whistling
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Schph Gochi (Phyllis Schulte)
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PostPosted: Mon Feb 11, 2013 11:08 am    Post subject: Reply with quote

lol..and..
again...
I am not a leatherworker...I will keep mentioning that because I hope it will give someone the idea to give leatherworking a try...
Again....I use really basic tools...
instead of an expensive leather scissors...
I just use a utility knife....
instead of one of the expensive skiving tools...I use a $4.00 corn shaver from the local Walgreens...
some tools are necessary to purchase...but they are not real expensive...



Now it is on to some of the other pouches that Luke has on his belt...

There is one tall pouch and two almost square pouches...

first had to make a pattern...and...again
I am guessing as to the size. I had PM'd someone at the MWG who posted a FB photo of a similar project asking for dimensions...or if they found a tutorial..and..the pm was opened but the person never replied to me....
so...
guesswork it is...

the tall pouch



the smaller square pouch




wet forming both pouches...













leaving them to dry now.....
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PostPosted: Mon Feb 11, 2013 11:20 am    Post subject: Reply with quote

love how this is going....
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Schph Gochi (Phyllis Schulte)
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PostPosted: Sun Mar 03, 2013 8:50 pm    Post subject: Reply with quote

I am not happy with how the pouches came out....
the wetforming process just didn't leave me with crisp enough bottom corners which led to stitching issues...

But
I did complete all of Luke's belt that I can for now...
The pouches come off the belt....so they are just floating on there...
but I will have to wait till I have Luke Z try in on before I can finish cutting it and putting in the holes for the buckle and also to install the lightsaber clip and d-ring as those are intended NOT to be moveable....so I will need to make sure of their exact location before riveting them on. I had to cut and gind down a spring clip to use as the lightsaber clip...

anyway...
here it is for now:


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PostPosted: Sun Mar 03, 2013 9:05 pm    Post subject: Reply with quote

Really nice work Phyllis. Very Happy
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sarah_d (sarah drummond)
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PostPosted: Sun Oct 27, 2013 10:41 am    Post subject: Reply with quote

Thanks for this tutorial Phyllis!!!

I've not worked with leather before and followed your tutorial and pattern to make one myself for a Han blaster :-)


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Schph Gochi (Phyllis Schulte)
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PostPosted: Sun Oct 27, 2013 1:12 pm    Post subject: Reply with quote

sarah_d wrote:
Thanks for this tutorial Phyllis!!!

I've not worked with leather before and followed your tutorial and pattern to make one myself for a Han blaster :-)



Awesome!!

I knew you could do it....
it looks great...
and you will only get better with each project...

Very Happy
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