This write-up will detail how to integrate the Nerf Secret Strike AS-1 into a Nintendo Zapper. This modification is not intended to maintain complete functionality of the Zapper.
The credit due:
The only other Nintendo Zapper topics I have found are one by Lion here, and another by Jangadance here and here. There is rumor that OMC made one to shoot darts, but I did not find anything beyond the rumor. The blaster created by Lion, while incredibly innovative, is not based on an authentic Nintendo Zapper or readily available blaster, "only gets about 5 feet," and although I will not post ranges mine gets significantly more than that. Additionally, Lion mentions that his Zapper is cocked by pulling the cord on the bottom (which makes it pretty cool looking), while mine functions differently as you will see.
You will need:
Nintendo Zapper (Im not sure if newer imitation models are constructed the same way)
Secret Strike AS-1
1/4 Vinyl Tubing 12 should be enough
17/32 Brass Tubing 3 3/16 or 3 1/8 in length
Welder Glue or Plumbers Goop (they seem to be nearly identical in application):
Dremel. I used the disk cutter primarily.
X-Acto saw (optional)
Thin plastic sheeting. I used white styrene, but polycarbonate should work too (less than 1/16 thickness) 6x6 should be enough.
Light gray spray paint
Drill and bits
Hot glue gun and glue
Phase 1: Open and clean out the Nintendo Zapper
Here is the Zapper:
Remove everything inside except the trigger and this is what you will have left:
Using a Dremel or similar tool, cut away all of the internal plastic parts except the parts shown in blue. Be careful how deep you cut away the plastic as the handle is particularly thin plastic. I would also discourage using pliers to twist off the pegs, since this can crack the case; just use the Dremel:
Phase 2: Trim down the gray pieces.
You should do this by placing each gray shell in its corresponding orange shell and marking a line on the gray pegs as close to the inside of the orange shell as possible. Now simply cut the gray pegs at the line so that the remaining nubs are flush with the inside of the orange shell:
Now get your sheet of plastic and draw 6 circles of about 3/8 diameter on it. I recommend using a stencil as is seen in the picture:
Cut the circles out and paint them:
Welder glue the circles to the nubs as shown:
Phase 3: Modify Zapper Trigger
If you remove the plate you will see that the trigger looks like this:
Trim the trigger above the blue line and remove the screw mount indicated by the arrow:
See this picture for a better idea of how far to cut:
While you have the trigger assembly open, You need to create a wedge that will activate the trigger more effectively. I cut one wedge from the thin sheet plastic and used it as a template for several others:
I glued them together with Welder glue, let set over night, and trimmed to fit with X-acto knives and my Dremel. The number of sheets to be glued together will vary based on the thickness of the sheet you use, but make sure the final product is about the width of the existing white trigger piece. Place the wedge in the trigger as in the picture. There is no need to glue it in place:
Edited by Gym, 09 June 2009 - 11:10 AM.