Now working on a full ESB buildup for a US Fett who wanted more pew pew for his buck. To that end He sent me a chopped down (save on postage!) Hasbro blaster toy to use for the light and sound gubbins. When I got it I was pretty impressed with the sound quality and volume from a cheapo toy.
First I stripped out the electronics leaving what you see here:
Battery case, speaker, circuit board and single ultrabrite LED. All these parts will be going inside the barrel cavity.
The trigger switch is built onto the board which is no good for mounting in my kit due to space restrictions, so the blue and white wires were soldered on to allow a micro switch to be connected to it.
I hollowed out the relevant areas in the Webley frame and inserted the switch, modifying the trigger part slightly so it acts on it when pulled. The fake resin screw was replaced with a real one to act as the trigger pivot. You can just see the top of the microswitch:
I've found the speaker is a perfect fit in the barrel but will need careful positioning along the length to provide the best sound as the hollow barrel changes the sound depending where you put it.
The battery case will need the four lugs removing for it to fit in the barrel - I suspect these hold it together somehow so i'll probably need to sort that one I chop em off.
SAS