Star Trek TOS Phaser Rifle

Discussion in 'Science Fiction & Fantasy' started by bgt01, Mar 24, 2014.

  1. bgt01

    bgt01 Exemplary Confidant

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    To create the clear sleeves I used .007 Clear-Lay 8.5 x 11" Film by Grafixarts. I bought it at Hobby Lobby. I thought about .015 clear plastic (too thick) or some overhead projector acetate or office supply sheet protectors (too thin). I even cruised the stores looking for some kind of plastic container/packaging on some product that might work, but that was a complete bust. In the end, the .007 film worked really well by bending easily while still being strong and clear.

    To get the clear on as straight as possible I placed each sheet flat on my cutting board with the edges lined up with the lines on the mat. I put some Super Glue gel on the white ends of the cylinder and set it square on the edge of the clear film.

    NOTE: As part of my planning I made sure as I assembled each part of the cylinders I kept the seams of each part lined up so they are all in line with each other. This played a big part at final assembly.

    I slowly added small lines of the gel glue onto the film in front of each white end and slowly rolled the cylinder forward. I kept steady pressure on the film and allowed more than enough time for the glue to set before I repeated the process. Instead of trimming the film so the seams met up I trimmed it long so the film overlapped the old seam slightly. I tried to use the gel glue to glue the film together but it didn't hold. So, I went back to the tape and used a strip of transparent tape to hold the seam down. I was also careful to not get fingerprints or dirt on the inside of the film.

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  2. bgt01

    bgt01 Exemplary Confidant

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    The last (and easiest) part was to glue the three cylinders in place. I chose to put the red one at the top because that's how it looks when Kirk blasts Gary Mitchell! I positioned all the cylinders so the seams faced inward toward each other so you really can't see them. Now I have lovely straight, smooth cylinders.

    First, I glued the cylinders to the back piece using regular Papercraft Gel Glue at the center and Super Glue gel at the edges. I used little dabs of Super Glue gel where the cylinders touch to lock them in place. Finally I glued on the front section, using my desk to keep the whole thing level.

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  3. bgt01

    bgt01 Exemplary Confidant

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    MAIN ASSEMBLY

    I attached the bottom "U" shaped part of the housing to the front and rear body parts after attaching the cylinders. If I'd done the cylinders last there's no way I could be sure they'd fit in the opening. I used a liberal amount of glue on the bottom piece, positioned it where I wanted and set the top part down. Using the desk to keep everything level, I pressed down with even pressure on both ends until the glue set. I let it sit overnight, then went around the edges with a slight bit of Super Glue gel on a toothpick. That locked everything in place. Then, I put some Super Glue gel on the base of the barrel and locked that down. She's really looking like she means business!

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  4. THE DC

    THE DC Member

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    Making notes on all your processes; including the substantial contribution of Twix, evident in the corner of the first photo (f.1)...

    Really enjoying this thread.
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  5. zathros

    zathros -----SENIOR---- Administrator

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    This really is quite a work. The colors and feel of the model. It's really excellent. :)
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  6. bgt01

    bgt01 Exemplary Confidant

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    @THE DC : No Saurian Brandy so I went for the chocolate buzz. Left and Right Twix were consumed with no preferential treatment.
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  7. THE DC

    THE DC Member

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    Well, at least you're organized in your addictions!
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  8. spaceagent-9

    spaceagent-9 Right Hand Man and Confidant

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    looks great! needs a dollar tree laser hooked up to a radio shack sound memo in the barrel !!
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  9. bgt01

    bgt01 Exemplary Confidant

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    STOCK

    I was unsure how the stock was going to turn out since it had such an odd shape, but it’s not too bad. As previously done, all the parts were glued to 1mm chipboard, the edges were trimmed to about a 45 degree angles, scores were done with an angled needle file and everything was edge colored with black Sharpie.

    The center piece is a simple box shape with angled edges to match the curve of the outer frame. I scored it on the back with a file as done previously. To know where I had to score, I marked the fold lines on the front with an ink pen. I cut triangles at the marks to give me points then lined up my ruler on the back at the points. That showed me where to score. I glued it all together with Super Glue gel. I used a BBQ skewer to put Super Glue on the inside seams for extra hold.

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  10. bgt01

    bgt01 Exemplary Confidant

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    I used the same triangle-cuts method to score the side piece. I cut out the center first, then carefully cut out the outside edges being careful to cut easily and not tear the piece.

    Once the outside skin was cut and scored I glued it to the edge piece starting one of the folded edges. From there everything was slowly glued in place using a sharpened toothpick to apply Super Glue Gel. More Super Glue went on the inside seam.

    The inside skin went on in the same manner. I eased it into place and got it all lined up before gluing the edges with Super Glue Gel. I was afraid the thickness of the chipboard would throw everything off but it went together pretty well. From there the center piece was glued in place.

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  11. bgt01

    bgt01 Exemplary Confidant

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    To make it stronger, I glued the mounting button to chipboard, added scraps of chipboard to the inside, then glued the other side to chipboard. I scratched the ink away where the button glued to the handle since it’s printed on glossy paper and I wanted the glue to get a good “bite.”

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  12. bgt01

    bgt01 Exemplary Confidant

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    FINAL ASSEMBLY

    Finally, the handle and the stock are glued in place and I am ready to take out Gary Mitchell on Delta Vega! It’s been a long, slow build and I’m pleased with the results. It’s a pretty impressive paper model at this size. As usual, I see a lot of ways I could have detailed it out more but I probably would never have finished it. I’ll need to build some kind of holder for it. You can’t let it rest on the stock or you’ll pop the little mounting button off. You definitely need some shelf space if you build one at this size, as you can see from the pic of me holding it and defending my vintage Realistic stereo (that one's for you @zathros ). Hope you all enjoyed the build.

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  13. THE DC

    THE DC Member

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    Thanks much for sharing this great build thread; awesome tips and it was nice to see this full size!
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