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Boba Fett RotJ Blaster 1:1 Replica from Rubies Toy

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Boba Fett RotJ Blaster 1:1 Replica from Rubies Toy

Postby Spack » Sun Nov 12, 2017 3:49 pm

:evil: I've wanted to add a Boba Fett blaster to my collection for a while, but the decent ones are very expensive and the screen accurate ones cost a fortune. I decided I could probably knock something passable together using a Rubies toy and some plastic, and so another project begins ....

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First thing to do was to dismantle it and figure out what needs modifying. It's clearly too short, digging around on the web tuned up some photos including dimensions which show that the Webley flare gun part is pretty much the right size, it's the barrel and the stock that are too short. The barrel needs to be about 2" longer, and the stock about 4" longer.

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I decided to go with PVC pipe for the extension, but the internal diameter of the barrel is about 45mm and the largest pipe I could find was 40mm. But the couplers to fit pipe lengths together are dead on the right diameter once the push fit ends are cut off, so I've used two of those and a 6cm length of 40mm pipe to connect them. The two blaster halves were cut with a hacksaw and the pipe glued in with PVC pipe weld, and some 20mm pipe glued in as the inner barrel - the front of the barrel was also drilled out so the inner barrel would be visible.

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Due to extending the barrel the scope was now too short, so I extended that too. The scope tube was 20mm so the 20mm plastic pipe used for the inner barrel was perfect. The mounts and scope ends were sanded out, and the adjustment knobs cut to fit. Everything was glued together using pvc pipe weld and left to dry.

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Will leave it all to dry before the next step.
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Re: Boba Fett RotJ Blaster 1:1 Replica from Rubies Toy

Postby Spack » Thu Nov 16, 2017 7:08 pm

The extension needs T track adding, and I had pvc L angle strips kicking around in my shed, so I decided to user some of that to fill in the gaps.

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The top of the barrel needed a new recess for the front scope mount, so that was cut out too.

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The L shaped cutout in the T track at the front of the blaster needed to be bigger to suit the longer barrel, and the front filled in.

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Carried on adding fill pieces to the first side, still need to do the other side.

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Re: Boba Fett RotJ Blaster 1:1 Replica from Rubies Toy

Postby Spack » Mon Nov 20, 2017 10:05 pm

More T track added to fill the extension. First up, here's what each piece looks like, approx 50mm wide, 6mm high, and 10mn deep with a bend in the middle so it will sit close to the curve of the inner pipe piece.

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Managed to finish all the T track, it looks rough because it's a skeleton for the epoxy putty that will form the surface to be painted. This will be left for a few days to make sure the glue is fully set before the putty is added.

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I also cut the stock and started extending it. From rough measurements of photos of the screen used EE-3 and the Master Replicas version I decided to go with a 3" extension. First thing to do was to cut one side in half, and then I glued in some lengths of square conduit I had sitting in the garage. The conduit is nice and straight, and will also resist bending a lot more than a flat strip would.

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When the glue has fully set the same will be done to the other half, making sure to line it up with the side already extended. As the bottom edge of the stock is curved it will need to be reshaped , I'm still figuring out how that will be done but I do have some plastic oval conduit that might work if cut in half.
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Re: Boba Fett RotJ Blaster 1:1 Replica from Rubies Toy

Postby Spack » Tue Nov 21, 2017 10:13 pm

The stock didn't quite look or feel right with a 3" extension, and after looking at photos of the screen used blasters and the Master Replicas versions I decided to reduce the extension to 2". Also took this opportunity to angle the shoulder end of the stock upwards sightly so the top edge isn't as flat as the Rubies was, and this also helps to reduce the difference in angle of the bottom edge.

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I've also cut the other half of the stock into two pieces and glued square conduit to one part of this to set overnight.

Next morning, with all the glue dry, the final stock part support had glue added and then the stock piece aligned to fit. Some scrap conduit was placed between the support conduit to force then apart, then clamps added to hold it together; the scrap conduit is springy enough to give way a little, but also push out to keep the glued conduit in place. The stock pieces were screwed together to stop them slipping.

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Once dry they will be unscrewed and taken apart so that the gaps can be filled.

Overall I'm happy with the proportions. It won't be entirely accurate but it should hopefully look less like a toy when painted.

IMG_20171122_055026220.jpg
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Re: Boba Fett RotJ Blaster 1:1 Replica from Rubies Toy

Postby Spack » Fri Nov 24, 2017 8:35 pm

Lots more gluing and clamping this week.

First the stock halves were reinforced with scrap conduit, this helps to make them more rigid and also provides support for the gaps to be covered.

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Using strips of pvc, heated with a hot air gun for a few seconds to soften then so they would bend easily, the sides were covered over.

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Finally the two halves were glued together and clamped. Strips of pvc will be added along the edges to stop the halves coming apart, then all of the pvc will get putty to smooth out the edges into the curves and level the surface with the original plastic.

IMG_20171123_205716077.jpg
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Re: Boba Fett RotJ Blaster 1:1 Replica from Rubies Toy

Postby Spack » Sat Nov 25, 2017 2:55 pm

Still some way to go, but here's how it compares to the original version, with the unmodified blaster at the bottom. The extensions are about 4.5" in total, making the total length 28.5" which is still a little short, but the proportions are better than before and the Webley part of the Rubies is a bit undersized.

comparion.jpg
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Re: Boba Fett RotJ Blaster 1:1 Replica from Rubies Toy

Postby Darklighter » Sat Dec 02, 2017 12:36 pm

Ooo Nice I've recently seen quite a lot of Nerf guns stripped and painted and I must admit I'm quite tempted to give it ago.
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Re: Boba Fett RotJ Blaster 1:1 Replica from Rubies Toy

Postby Angelwing » Sat Dec 02, 2017 4:03 pm

Looking good!
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Re: Boba Fett RotJ Blaster 1:1 Replica from Rubies Toy

Postby Spack » Sun Dec 10, 2017 6:04 pm

Last week I used Isopon P38 filler to cover the plastic that had been glued over the extensions, although I tried to get it fairly smooth it turned out a bit rough.

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Today I sanded it all as smooth as possible, and used an engraving bit in the Dremel to add the grooves between the T track details on the barrel. It still needs some tidying up, but I've given it all a coat of primer to help highlight the areas that need a little more filler to level them out.

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I also made a start on the sight rebuild, I've got some 20mm X 3mm clear acrylic discs to use as lenses and used the engraving bit to add some grooves onto the inside of the back lens. A little black paint was added to the recesses.

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I'll leave it to dry for overnight, hopefully I'll be able to get the filler finished tomorrow or later this week.
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Re: Boba Fett RotJ Blaster 1:1 Replica from Rubies Toy

Postby Spack » Thu Dec 14, 2017 6:38 pm

Almost at the end now. Spent some time yesterday filling and sanding, filling and sanding, etc. Today I've sanded everything again, and then used red primer to prepare for paint tomorrow. There are hanging up in the garage drying.

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The scope has also been adjusted again, this time to trim the mountings down so that they don't stick out as far. Pieces of plastic have been glued into the holes, and filler added. This will be sanded before priming, and screws added to the vertical faces.

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