I've finally started working on my Jango blasters. First thing I did was cut out three 1/2" thick aluminum handles.
Then I chamfered the edges that were going to be touching each other.
I welded the plates together, then routed the extra weld bead off.
Last one is for size comparison to my hand.
Next thing for the grips is to router a 1 1/4" channel along the top and use the 3/8 round over bit on all the outside edges.
I've got the easy parts for the barrels rough cut, but none of the slots have been routed into them yet. And I will still need to sand and polish the barrels. The barrels are 1" OD aluminum tubing and the double mitered pieces in the back are 1" ID 1 1/4" OD.
I haven't started the muzzle or power cell cartridge yet, but I think I'm going to buy myself a mini metal lathe in the next couple of weeks.