Several months ago I was looking for a project. I used to build things for a living and now I work in a more virtual environment. I was nostalgic for a hands-on, low-tech build of something... anything... and finally set my sights on an E-11 largely due to the amazing depth or resources available here on FISD. The criteria for the build were simple... create something cool with easily obtained materials and simple tools, build it with very little cost, have fun doing it and do it all without annoying the neighbors.
I created a small shop in the corner of my basement storage and armed with a dremel, cordless drill and hand tools, began creating my new toy. I've been working on it for an hour here and an hour there since late January and it's about halfway done. I figured it was about time to unveil my progress. Sadly, I didn't look at my build photos along the way and a lot of them weren't very good so I'll just cover the highlights of the build up to this point and try to be more diligent as the project goes forward.
I'm formatting each aspect with time, cost and a description of what I did.
The "Time to build" does not include r&d or do-overs and the "Cost of Materials" is based on the amount of material used for the actual build and doesn't include tools purchased or failed experiments. These numbers are basically the, "If I had it to do over tomorrow, I could build for this."
So... here we go...
_______________
The Tube - Part 1 Time to create: 4 hours
Cost of materials: €0.75
I went with a standard pipe build using readily PVC electrical conduit. I wanted the appropriate wall thickness of a real Sterling and schedule 40 PVC seemed way too thick. I found a perfect tube on my first outing and purchased a 2 meter piece of tubing for €2.95
Using a plans found on this forum, I imported the .pdf files into CorelDRAW and redrew them using the imported images for scale. I wanted the seam on the bottom instead of the top, as they were originally created, in case the seam didn't line up perfectly... and it didn't. There was a slight overlap and lining it up was more challenging than anticipated. I drew a line on the pipe (cut to length) and taped the plan along one edge to the pipe and spray glued the paper plan rolling around the tube after spraying and giving the glue a moment to tack up.
I drilled the vent holes using the stepping technique and all went fine until I hit a snag toward the end... my drill index used to go with my 1/2" chuck drill press I used to use in my old shop and my 3/8" cordless drill wouldn't accept the last four sizes I needed to use...
After a bit of thought, I decided to just try reaming the holes by hand to reach the appropriate bit size. I wrapped a piece of cloth around the bit and bore only took a few twists to bring it up to size. I advanced through the last few bits and got all the holes to the correct sizes. Granted, it took another hour plus and I felt it in my forearms for a few days bit, short of buying new drill bits (which I considered), it was my best option.
I scored through the plan with an Xacto knife to indicate the postions of the various other pieces such as the sights, ejection port, etc. and then cut the ejection port, and charging slot by drilling a starter hole and then repeatedly scoring the lines with an Xacto knife. I left the magazine side intact and would later drill a hole for wiring the electronics.
__________________