Pyrates

I cut the nail using wire cutters then smoothed it down with my file - go slow filing as the nail heats up pretty good and will start to come back out.

I had to create a stopper if I wanted to have a functioning bolt so I've cut a small stopper from 1" PVC scrap - you have to love freebies. I added teflon tape around the stopper to one: help fill the narrow space between the two pipes; and two: help adsorb a small amount of concussion from the bolt slamming against it. The little dot by the vent hole is a finishing nail, hammered in from the side of the blaster to stabilize the stopper

I want to just take a moment, if I may, to pay big time recognition to the FISD E-11 Blaster Reference - for without this thread, really this build would not be possible. Much appreciation and thanks to the grueling work of documenting all that information (not to mention helpful templates for scratch builds as you will see - the bolt detail above is from the guide) - Buckets off to all that made it happen. http://www.whitearmor.net/forum/topic/32111-fisd-e-11-blaster-reference/

Sorry mates; wee man has caught a cold so I've only been getting a few minutes here and there. Moving on, I've disassembled the mini saber to work on the length of the bolt - unfortunately I'm going to have to lose a few points on accuracy but the end result should make up for it.

I found these yesterday - Tactical underwear compression stuff ( a little more expensive) ----------

Hey mate - if you haven't already got a suit yet there's some "Everlast" compression stuff at Walmart - $14.99 for each top and bottom - $30 (I'm 6' - 215lbs give er' take) I bought the large and they're comfortable - avoid the Activ Walmart Special as their color of black is a bit off in the sun (looks brown/black) - cheers!

Redefining "Boom Stick!" - Awesome!

Many thanks mate for this thread!

Just placed my order - so stoked! Sent from my iPhone using Tapatalk

Looking awesome! Sent from my iPhone using Tapatalk

After cleaning the rough edges it became time to think of the inner components with future t-tracks going into the pipe and a decision if a functioning charging handle will work with the mini-saber (just to help add to the magic). It still needs a little more filing work but I will do that later prior to assembly So some modifications will be in order but I'm pretty sure I can get this to work

That vest looks mint and looks more comfortable than the one I served with. Mr. Hale would make a stellar "SAR Tech" for the military. Loving the progress on your BFG and can't wait to see the rest! Sent from my iPhone using Tapatalk

I've cut out the difficult pieces using an electric wood burning tool with exacto blade attachment and let me tell you this: time consuming (2 hours) but happy with the end results. The bolt chamber and charging handle area just need a little TLC (Trooper Love and Care) with a file to clean and smooth the edges.

Cheers mates! The mini sabers, funny enough, are Wii Accessories I bought for Force Unleashed from Walmart - they were $10 a piece about 6 years ago. Sent from my iPhone using Tapatalk

Kudos to all - this reference is priceless - Cheers! Sent from my iPhone using Tapatalk

I also used an engraver to lightly scribe the center lines, magazine, chamber, and cocking handle channel. Sent from my iPhone using Tapatalk

You gotta love it when you get surprises like this from the family

So after I took that pic I got an idea for the inner barrel...hmmm.... Gack! - NO WAY! As the Kool-Aid Man says "Ohhhhhh Yeeeeeeaaaaaah!"

Now to try and keep things as accurate as possible I used a 3/8" drill bit then used the edge of the bit to shave off the last 1/16". I used a drill press to speed up the process and for more control. A cordless power drill could be used instead of a drill press with use of a shorter length bit or a "Stepper Bit"

Keeping cost in mind - Gluestick $2 / Spray adhesive $18 Prepped vent holes with a punch ( a sharp nail will work too) and highly encourage to always use a clamp whenever possible