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PostPosted: Thu Feb 05, 2015 5:43 pm 
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This is all extremely informative for the rest of us, but must be torture for you! Good luck man!

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PostPosted: Thu Feb 05, 2015 6:34 pm 
BUG SPRAY
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Hmm, I have a similar piece of square tube sitting on my work bench with an awful lot of markings that line up with your slots. My welder hasn't been fired up in a long time.

Looking good!


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 Post subject: Re: Pulse Rifle madness! (1st up) - The "Hero"(ish) build
PostPosted: Fri Feb 06, 2015 8:44 pm 
THAT guy
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Thanks guys.

Did a bit of welding and cleanup today on the stocks. Let me warn you, when it comes to welding, I'm 'book smart', not 'street smart'. I realized today I'm a pretty terrible welder. Anyways, I tried 3 'wall' thickness of 1-1/2" tube.

-~10 gauge? (0.12" / ~1/8" wall thickness = Too thick. Maybe OK to make a vent, but not enough internal room to go over the Thompson.

-16 gauge, 1-1/2" square tube = A tad loose. If you want to save weight and plan to put something like felt or moleskin on the inside of the stock to prevent marring the finish on the Thompson, this could be a good option as there is just a tiny bit of wiggle room between the stock and Thompson.

-14 gauge, 1-1/2" square tube = Snug to Thompson. Maybe a hair too snug considering it's metal rubbing metal, but I like it. This is the one I think I will actually use. I may give it another crack and try all over later, but for now I need to get rolling on the rest and this is a huge upgrade to me over the HCG stock. This feels significantly more robust.

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 Post subject: Re: Pulse Rifle madness! (1st up) - The "Hero"(ish) build
PostPosted: Thu Feb 12, 2015 3:52 pm 
THAT guy
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The most minor of updates.

"Solved" (sort of) the problem of deleting the 'winder' from my metal mag.

Cut and sanded down a plastic mag (which uses a traditional spring feed) until it fit inside the metal housing. Now I just need to figure out how much length I can keep as I balance cutting the mag to fit the base vs. milling out the aluminum base to fit the mags.

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Also welded in some sling 'rings' to the stocks.
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PostPosted: Thu Feb 12, 2015 4:49 pm 
BUG SPRAY
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On your stock, I see that you drilled out the holes to start the slots. How did you finish the slots? Milling or cutting and grinding?


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PostPosted: Thu Feb 12, 2015 5:16 pm 
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Obiwan kowalski wrote:
On your stock, I see that you drilled out the holes to start the slots. How did you finish the slots? Milling or cutting and grinding?


After the failed milling plan, I just did it the old fashioned way. I drilled the holes on each side, started the slot cuts with my angle grinder (shallow, so as not to overrun the hole) then finished with a dremel near the holes ends. I do plan to take a carbide burr to it still to clean it up a bit, but I broke my narrow burr so need to get a new one for the dremel.


Last edited by bigbisont on Tue Feb 24, 2015 10:58 pm, edited 1 time in total.

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 Post subject: Re: Pulse Rifle madness! (1st up) - The "Hero"(ish) build
PostPosted: Tue Feb 24, 2015 10:44 pm 
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more boring stuff on this update. Boring, but necessary.
Attached the stock!

Started by just widening the existing holes used to mount the rear sight then inserting a regular nut and bolt combo.
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Realized quickly this would not fly with the airsoft internals. The front bolts not only blocked the lower from being re-attached properly, but the nut actually blocked the cocking handle from coming back. I had to complete remove the front set of bolts.
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The good news is the stock is very snug already and the CGW shrouds actually grab pretty tight all over so the 'top plate' I have seen in other builds is unlikely to be needed. It was so tight that I actually had to remove some material at the bolt cap area to even get the shrouds around it.
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I think it is in there pretty solid. I have not yet decided if I will make a locking mechanism for it to lock into different positions. I will just leave it in the closed position primarily, so it doesn't bother me right now.


Also drilled and cut out my front vents. The "milling" of the indentations did NOT go well, but I still hope I can clean it up and salvage it now that the heavy cutting is over
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(again, 16g and 14g so I can see what I like better)


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PostPosted: Wed Feb 25, 2015 4:40 am 
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How cool is that?? Seeing the shrouds on (even just on the back) is very exciting.

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 Post subject: Re: Pulse Rifle madness! (1st up) - The "Hero"(ish) build
PostPosted: Fri Feb 27, 2015 4:57 pm 
THAT guy
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This has been the part that most freaked me out to think about. It was the part with the least info on (at least in my searches). I could find NOTHING in the way of pictures how people did it. Only one sentence lines about "I made a spacer".

Connecting the SPAS grip to the 870 sliding arm through the SPAS cage is the part I have dreaded a long time, and it did not disappoint.


While a simple spacer is actually all it is, the level of precision needed here was enough to drive me mad.


First up is the base 870 arm. Once you remove the grip from the slide, you are left with this arm and gigantic tube. You actually have a lot of wiggle room for where you want to cut, but I thought leaving about an inch of tube past the main ring would give me some extra anchoring points and I was glad I did it.
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Next up is arguably the most important part, because this is the part you see. A little dremel work, a little patient and slow utility knife work, and a tiny bit of drilling and you can work out your rectangle recessed area on your grip. This is also where you will be deciding your bolts go. Try not to mess it up! :wink: Where you put the holes will also determine where your forward position is on the finished product.

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(The steel rectangles were shaped from leftover 14g steel from the stock project. 14g feels thick and sturdy but wasn't prohibitively huge needing a gigantic recess in the grip, so I liked it)

Now to make the actual spacer. I cut this from a 3/16 chunk of steel (the SPAS slots are 15/64" wide, 1/4" is too big) and cut the notch in the middle so it would straddle the main ring. I think some material in front and behind that ring will only help structurally so it isn't the bolts alone bearing the force during racking.

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Once you like the 'fit' of the spacer on the 'arm ring', you drop the whole thing into place and see how the height works. I grinded it down to just enough where the slide could barely go over it so it so it was nice and snug.

When I had a good height and was happy with the fit, I dropped a fine tip sharpy down the holes on the grip and marked where the holes on the spacer will need to be drilled out. I think it is important to put one of the bolts right through the center of the main ring on the arm for strength reasons. That is a tough steel anchor point there (as I will explain shortly).



To get a good clean hole drilled then tapped, I couldnt have the spacer bouncing around, so I did decide to weld it in place. This was a nightmare. 5 tries. Too high, too low, too crooked, you name it. Actually on the 3rd try I got the spacer exactly where I wanted it. Drilled the holes exactly where I wanted them. Then when I tried to 'tap' and thread the holes... the f'n tap broke off IN THE HOLE the instant it hit the "main ring"!!! :evil: I had to dremel off the block entirely and trash that spacer. I had to start all over again making a new spacer, drilling, and tapping (this time more carefully. Steady pressure when tapping the steel! No quick movements and always remember to back it out occasionally so the shavings can settle into the grooves!)

So please...be kind and ignore the welding job here.
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So if you measured everything correctly, you now have a "Grenade Launcher" grip that bolts directly too the slide arm of the 870. If you welded it in place correctly, it slides freely back and forth in the extra long slit that was cut into your SPAS cage.

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One other bit of potentially useful info: I used a 6-32 threaded flat head hex bolts on this. The heads do look a bit small to me compared to some of the images of other pulses, but anything bigger than that will simply not fit in the 3/16" steel spacer. I assume its a metric thing where a spacer made from 5mm steel (just a hair larger than 3/16, but still fits in the 15/64"/6mm slots of the SPAS) might be able to take a bigger bolt.

* I have 3/4" length bolts pictured which proved too long. A 5/8" length, 6-32 thread bolt proved perfect.
**Ignore home depot and lowes. They don't have ANYTHING useful for this project in the way of bolts. Find a mom-and-pop or an ACE True Value.


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 Post subject: Re: Pulse Rifle madness! (1st up) - The "Hero"(ish) build
PostPosted: Mon Mar 02, 2015 7:16 pm 
THAT guy
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Location: Virginia
Service Number: A03/TQ2.0.02146E1
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The barrel proved to be the ultimate 'compromise". I wanted to do a screen accurate style extension of the existing Thompson barrel. This proved problematic for 3 reasons.

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1- NO room to 'thread' anything. The brass inner airsoft barrel is snug inside the Thompson barrel. Far too snug to fit any tube or anything threaded object in there while leaving the airsoft barrel operational

2- Dissimilar metals. I thought I might just weld the barrel extension on, but this would never work as the Airsoft Thompson has an aluminum barrel. The barrel tube I got was steel. They cannot be properly welded or brazed. I could have found an aluminum tube to extend the barrel, but aluminum welding is exceptionally costly and difficult. I highly doubt I would have ended up with a good looking product anyways (look no further than my welding in the previous post..)

3- Strength. I could have just rigged it up with glue, epoxy, or steel stick and trusted the barrel vent to support the front to complete the look, but I really really want to be able to 'sling' the weapon and let it hang via a sling despite its exceptional weight. The barrel is going to need to be an active participant in the weight support from the sling mount.


So...I decided to "replace" the barrel after all.

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I think this will be exceptionally strong and work for 3 reasons!

1- As seen in the pic, the 11/16" tube I selected is itself a compromise between the thinner main Thompson barrel and the thicker barrel extension. It looks robust and I can still notch the front. I like it.

2- Also as seen, using the rear end from the original barrel acts as a mounting bracket that provides 3 points of contact for the barrel. I cut it so the most forward part is very snug to the barrel. The steel barrel itself is very snug under the original mounting point AND the old bracket fits snugly over the original mounting point. Overall its all sandwiched in there very tight

3- It can be "blued". I'd like to 'blue' my metal parts. Using the aluminum airsoft parts would have forced me into painting unless I ran with mismatched colors. Now the entire barrel, vent and stock will be uniform.



The only drawback (besides not being technically screen accurate) is the front support post for where I planned to mount my grenade launcher had to be removed. With only the rear part supported, the 'tab' where my GL bolts to wiggled quite a bit. To help with this I put a brass strap round the front near the mounting point and riveted it in place. I think that tightened things up enough to continue with the plan to mount the GL there. I hope...
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And I continue to drill, grind, dremel and hammer my vents. Still a bit ...imperfect. But this is what will give it "character" like the real ones, so I like them. Plus they are much better than the one I made 3 years ago!
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Tonight I try to bolt the cage to the vent and weld the 'ring' in place.


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 Post subject: Re: Pulse Rifle madness! 1st up: The "Hero"-ish one ALMOST D
PostPosted: Tue Mar 03, 2015 1:50 pm 
THAT guy
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For the first time ever, I fully mounted the grenade launcher.
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It feels pretty solid and 'racks' perfectly!

So at that point I couldn't resist and just had to dry fit everything together.

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I still need to weld the front rings on the vent, paint the SPAS, blue the steel, figure out the mag base (my last big headache right there), and re-thread the screws to assemble the shrouds (for those not aware, the shroud screws were practically decorative on the HCG as they were glued in place as the screws were dropped into oversized holes filled with resin. They did not unscrew cleanly and the original holes are not usable in their current state.


Last edited by bigbisont on Wed Mar 04, 2015 7:50 pm, edited 1 time in total.

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PostPosted: Tue Mar 03, 2015 3:10 pm 
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That looks soooooo awesome!!

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PostPosted: Tue Mar 03, 2015 3:17 pm 
AKKURAZI
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Country: Germany
That is going to be such a sweet sweet hero PR, I can't even begin to give it the praise it deserves.
Man, I too need a SPAS/Remington assembly working like the one you have there. But: not gonna happen on German soil...


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PostPosted: Tue Mar 03, 2015 4:15 pm 

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Awesome progress. I am just starting mine so it is an inspiration!


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 Post subject: Re: Pulse Rifle madness! 1st up: The "Hero"-ish one ALMOST D
PostPosted: Tue Mar 03, 2015 8:27 pm 

Country: United Kingdom
great looking work. you've achieved and surpassed in a few weeks what has so far taken me nearly two years to do.

looking forward to seeing the finished piece.


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 Post subject: Re: Pulse Rifle madness! 1st up: The "Hero"-ish one ALMOST D
PostPosted: Wed Mar 04, 2015 7:47 pm 
THAT guy
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Well thank you very much guys. In the home stretch now!


Even though I couldnt do a screen accurate barrel 'extension', I did pull off the front notches to simulate the look. I think it looks solid.
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Also the bigger news is I welded up and blued my steel parts. I forgot to mention I snagged the idea of bluing the parts from Stapleton13's build I saw several ears ago. It always made an impression on me and glad I finally pulled off the feat myself!

And boy howdy, I want to go home and blue everything in my house now! It looks sooooo good 'blue'! It hides the imperfections without hiding detail and just looks "gun-like".

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By contrast the SPAS and block were just sprayed black. I am going to buff them with steel wool to fade that intense black down.
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Last 2 items on the list
-Sort out the mag base to mag attachement
-Button it all up with a better solution than gluing the bolts in place (which the HCG did)


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 Post subject: Re: Pulse Rifle madness! 1st up: The "Hero"-ish one ALMOST D
PostPosted: Fri Mar 06, 2015 2:58 pm 
THAT guy
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Location: Virginia
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I wasn't happy with the M3 bolts the HCG came with anyways (too small, not to mention coated in epoxy residue) so I filled in the holes around the magazine portion of the shroud with steel-stick and then re-drilled and tapped them for a larger 8-32 bolt. I am pretty happy with the results and everything screws down pretty solid now.

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I relocated the rear plate a little lower as well. I think it was a bit high originally and with it lower I could drill/tap solid aluminum for more strength around the bolt.


So while I have not yet sorted out the magazine or solved the battery placement issue, I have buttoned it all up to test it. I haven't torture tested it by spinning it around by the sling just yet, but so far so good! Zero wobble and everything is ROCK SOLID.

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With any luck I will have it 100% complete this weekend.


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PostPosted: Fri Mar 06, 2015 3:07 pm 
AKKURAZI
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Now send it my way. ;)


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 Post subject: Re: Pulse Rifle madness! 1st up: The "Hero"-ish one ALMOST D
PostPosted: Mon Mar 09, 2015 8:21 pm 
THAT guy
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Got the magazine sorted out!

Went ahead and chopped some more 'guts' parts so I incorporated the "U" turn so more rounds would fit. Slid it all in the metal housing.
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Drilled, dremelled, and once again tried to mill out the material from the aluminum block I made so that it worked as a "cap" mag base.
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I'll spare the gory pics, but I nicked my finger on the 5/8" milling bit. What project would be complete without a helping of your blood to pair up with your sweat? Right?! Anyways... mag base is done! Epoxy is drying as I type this.
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ALSO got the electrics done. I didn't do anything new or unique here. I dremeled out a groove so the wires could go up into the big area on the front pillar. I used the 2x AAA and holder from the mag. I trimmed up the 'holder' so it would be a bit smaller and dremeled out the studs I had previously ignored. Its very tight, but it does fit and closes up.
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I am really tempted to try a CA2450 button cell battery. The AAAs are 1.5v each (3 total) while just one of those button cells is 3v. I would assume the downside is it will not last as long? Anything I am missing here electrical guys?

I may switch to the button some day as I could fit that somewhere that it could be replaced without taking the entire shroud apart, but the deed is done with AAA so I am not stressing it too badly.

So tonight more paint, more weathering and finally glamour shots!!! (and maybe even a video)


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PostPosted: Mon Mar 09, 2015 11:51 pm 
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Does it count down?

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PostPosted: Tue Mar 10, 2015 12:13 am 
THAT guy
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retrogarde wrote:
Does it count down?


Na. I do have a Majenko board but I am planning on running it on my lightweight build where id like to incorporate sound. I might break down and swap boards later though.


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PostPosted: Tue Mar 10, 2015 12:26 am 
Prop Churner Outer
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That post got interrupted by a child-related drama. I meant to say "holy heck that looks awesome!"

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 Post subject: Re: Pulse Rifle madness! 1st up: The "Hero"-ish one ALMOST D
PostPosted: Tue Mar 10, 2015 12:53 am 
THAT guy
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Lol it's all good. Thanks.


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 Post subject: Re: Pulse Rifle madness! 1st up: The "Hero"- FINALLY DONE!
PostPosted: Tue Mar 10, 2015 3:55 pm 
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In typical fashion, the magazine jammed when I tried to get a shooting video. The feed spring is stuck in the middle somewhere so I may have to completely rip it back apart and re-do the mag. Oh well, it is all together! If I do get the video of the firing and shell cycling I will update the thread, but I am most def done with this thing for a while. Thanks for following.

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PostPosted: Tue Mar 10, 2015 4:03 pm 

Location: Bethlehem, Pa
Service Number: A08/TQ1.0.12261E1
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Absolutely beautiful pulse rifle, your hard work has really paid off so far...and now I want one (thanks a lot).

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