Begin with a holder, I like a piece of wood with 1/2" holes drilled in it, other people like 1/2-3/4" pieces of PETG, it depends on what you prefer. This particular one holds 200 blanks.
Filling 200 holes with blanks takes a while, I suggest watching TV or something while you do it. It's a mindless activity.
This is the trick that I discovered a little while back. A cheap little Weller soldering iron will make a hole that's just about perfectly sized for a Copperhead BB. You just have to be careful not to keep it in the foam too long or it will melt everything around it and make a larger hole.
For Single BB darts, a quick dip about 1/4" in will work perfectly. For Type D you need to go about 1/2" as quickly as possible to avoid overmelt, and for type S you need to go in about 3/8" and hold for a second so a larger diameter is created.
Once the holes are made, insert your chosen weight. Notice the difference in the hole size from the top row to the bottom row.
Then you fill in with hot glue and you're all done. Top row is Single BB, Second is Type D, Third is Type S.
You just have to be careful not to let the hot glue gun sit for too long or it'll get so hot that it'll melt right through the dart. You want the glue to be only semi-liquid, not running like water.
So there you have it, that's how I do my stefans that I both use and sell. Hope you enjoyed.
