WIP: Sidearm scratch build attempt

Yesterday, I was waiting for paint to dry on my chest armor and started looking through the jet pack templates to get a game plan, when I came across the WOF sidearm templates. Since I've never attempted to scratch build anything like this before, I figure I'll start with something not as intimidating as the jet pack. So, here we go...

1st- I printed off the WOF templates. Alan seems to have made this look relatively easy...:) All the templates are labeled with the thickness of each piece. For this build, I have choosen to work with 1/8" (3mm) Celtec, which I understand is very much like Sintra. Once I printed the templates, I cut them out.
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Then I traced them onto the Celtec.
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Now it was time to give the dremel a little work out! It was 103 here yesterday so I decided it would be smart to do this in my office...:lol
This stuff gets EVERYWHERE!!! and sticks to EVERYTHING!!! Don't do this in your house. Your wife won't be happy!

Here's the cut out pieces.
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I was watching a RKD video the other day and he recommended this stuff:
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So , I followed his lead. Seems to work pretty good. I just mixed it like any other epoxy and smeared it in the pieces and clamped them together.
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From here, I just dry fit the rest of the pieces, so I can figure out the best plan of action.
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Let me know what y'all think...

So here's what I'm thinking this morning. I'm going to glue up frame and grip pieces, but not the upper rail or or lower rail (technical terms...:)). This will allow me to drill through the frame and trigger (gotta figure out a spring for that too...) and cover the pin with the upper and lower rail. Or, should I attach the upper and lower rail and drill though them so I could remove the trigger in the future should I need too? Not sure why I would need too, but always nice to have options! :)
Once I figure this part out, I will sand it down and then hit it with bondo (something else I've never worked with) and sand it again.

Thoughts anyone?

Looks good mate, might give this a try myself. Will be watching how it all turns out.

Phantom- thanks bud. So far so good. I clamped it all together and started sanding. I'll get some more pics up when I have some more progresse.

This might be my only course of action since no one is making them and when someone sells one it's either too expensive or gone in a split second. Keep us posted and it looks pretty good so far.

Jc27- Thanks, and you hit the nail on the head. I haven't seen one that fits my budget, so I'm making it my self. I really feel like Alan did all the hard work with the templates. Once you glue them together, it's just sanding and dremel work. Still haven't figured out the spring for the trigger or if I'll even go that far, but it's starting to take shape.

Very nice build. I might try something like this when the time comes. I see you traced the templates onto the board. Any specific reason you did it this way? When I use the templates I just rough cut them and then glue them on with elmer's glue. After they're cut out the paper just pulls off.

Thanks Matt! Your thread on the jetpack build is what actually encouraged me to give this a try. As far as the templates, no reason, just made sense that they couldn't move or come off if they were drawn on to the plastic. I may try your method for the jetpack build I plan on doing next.

I haven't had a lot of time today but here's what I got accomplished... I trimmed up and fitted the trigger. Drilled the hole for the trigger pin. And laid some bondo around the handle and trigger guard. This way I can finish up the trigger area, install it and glue the lower rail on each side. This will allow me to really start shaping the components.
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This is awesome. :thumbsup

Nice stuff mate. Going to go and try and find some 3mm plastic next week and give this a good go. I do have a nintendo gun I was going to mod but this looks a lot better, can always fall back on the nintendo one if I stuff this up :)

Phantom- I hadn't thought about a Nintendo gun. That's a pretty good idea. I think you'll find that this stuff works pretty easy and pretty quick. I haven't had a lot of time to devote to it, but she's moving along. :)

I went ahead and added the 2 side pieces and and drilled through them for the trigger pin and then set the 2 rear side pieces. I also cut some pieces for the frame work on the top or cap pieces that will enclose the bolt.
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Then I cut out the rest of the frame work and glued it up.
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While that was drying, I took a 3/4" and 1/2" sanding bit and routed out for the bolt. I decided to go with 2 separate pieces since you don't see where they connect and I don't have to find 2 pieces that "marry" together perfectly... Hopefully this will make it easier in the end :)
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I am pleased with the lines and they way she is starting to come together!
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Here it is with the top cap glued in place.
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Now I just have a lot of sanding to do before I hit it with bondo. Hopefully I can get that done tonight or in the morning.

I know this post is only an hour or so later, but I couldn't wait to start sanding! :lol
I put a reference picture in the back ground for comparison as well as the WOF assembly file.
Let me know what y'all think!

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Anybody know what color to paint the side arm? I'm looking for a rattle can color. Thanks!

She's starting to look like a side arm! I used 1/4", 1/2" and 3/4" dowels for the bolt, bolt pin and barrell. For the knurled piece on the barrel I used a battle cap.
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Here's a picture with test colors. I think the orangey reddish color will work out once I get some walnut stain rubbed on it. I test painted the barrel to see how the bright silver was going to look. Again, I know I need to weather this thing with some walnut stain, but I can kinda see where I'm headed now!
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Looking great mate....well done!!

Excellent job! Love it!

Thanks Phantom and Raf!!! It's been fun, but ready to move on to the JP!

Once the bright silver dried, I found out that I didn't sand the dowels enough. I could still see the wood grain through the paint. So I started sanding and then thought I better take the opportunity to see how the weathering will look. I rubbed a little walnut stain all over it. I found out that walnut stain will take the paint and primer, right off the plastic if you rub too hard! Oops!!! I think the waethering is going to have to be done in stages to get it dirty enough. Here's the pics...
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Got the base coats down. Going to let it sit overnight and start the weathering tomorrow. :)

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Great job bruv, I like the colour...
Just needs a little weathering. :thumbsup

Thanks Mojo! I really got lucky with the color as I don't have and airbrush (soon to be remedied!) and am slave to the rattle-can at the moment! :) Just happened to be a primer color that Lowe's had.
Overall, I'm happy with it.
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So after a successful burn test today (I love my job!), I got to work weathering. I laid a coat on both the bright silver and the red oxide. Then after an hour or 2, I inspected and reapplied to the red oxide only. I think she's just about there. Let me know what y'all think.
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Looking much better bruv... more 'used' ;)

Thanks Mojo- I'm wondering if I did too much???

If your not 100% happy with the weathering you could always take it back a little with some very fine wire wool (lightly) to get some gradients in depth of weathering?
There is next to zero reference pictures of the sidearm 'out' of the holster it is hard to tell and lends itself to personal preference.

Good idea on the wool. I think I'm going to let sit a day or 2 and see what I think then. I'm happy with the silver, just not sure on the red oxide just yet.

I agree let it sit with ya for a couple of days and see how you feel, plus you'd want the paint to 'cure' properly before any rubbing with the wool.
Shown below is what I did for a commission based on the sidearm I did along with a ref pic? may help?

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Looks great bro! Did you hit that wool? I think part of why I'm not super happy about it, is the way the grip looks. I know yours is cast, but I really like the texture of the grip. I think I might try to tape up some plastic and see how well it takes a texture. Or I could heat it and try to imprint a texture on it. Maybe??? Or I guess I could go buy a grip and glue it on there... Gonna have to move away from it for a bit. Maybe work on that jetpack... :)

Cheers, but I think the advantage of the Pulce is that it has the textured grip, so it allows for more depth of weathering.
I know what ya mean about possibly stepping away, come back with fresh eyes and intentions.. lol

WOW....looks fantastic mate. When I get mine going hope it turns out half as good.

Maybe if you want texture on the grip can you get some thin textured vinyl or something to glue on ot maybe spend some quality time with your dremel :)

Phantom- Thanks bud. Vinyl isn't a bad idea. My wife suggested paintball grips... Gonna chew on this one a bit. :)

Nice work! This is one of the reasons I came over here from the RPF. I need to build myself a sidearm for my ESB fett and I found that most sidearms are just too spendy and disappear too quick! Thanks for the nice series of pics. Gives me something to follow and keep me out of trouble! Thanks for posting this build!

Psi- thanks bud, glad to have you over here. If you have any questions, feel free to ask.

Great pics, your sidearm is awesome. Makes me want to attempt to build my own as well.

Thanks Bayne, it was a fun build. Gave me a lot of confidence!
Good luck!

this is definitely on my scratch build list. this thread convinced me.

Thanks Division! Glad to help you make that decision! :) Let me know if ya have any questions.

Hey Dechels nice wip I bought a sidearm off the Bay back before I knew better and with this thread as a guide I'm gonna mod it . I need to get a few items at Lowes and I'm all set. Thanks for this it's a big help!

G2BF, thanks bro! I almost did the same thing. Looks like those they sell on the bay might be a good base to mod. Love to see your work when you start! :)

I've gone back and forth on what to add or change and finally decided to hit it with some 4000 grit sandpaper, a light wire brush in the cracks and then a clear flat coat. I think I am going to move on to the knees and jet pack! I will visit this again when I start upgrading things! :)

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Looks fantastic mate....well done.
I think you have inspired a few of us to give this a go. Thanks

Thanks Phantom! I hope I can do the same on the EE-3 I'm planning and the JP that Matt inspired me to build. Holler if ya need anything. :)