::Disclaimer, I'm really tired right now, so some parts of this may be a bit unclear. If anything is confusing, just let me know and I'll do my best to remedy the situation.::
::See bottom for firing video::
First, you need to download and print your Templates
Make sure you have everything from the Parts List.
1) Cut them out, paste them onto your plastic. The two plain circles with yellow coded centers are from 1/8" thick polycarb.
2) Drill out the holes and cut out the appropriate parts, as per the legend and templates. Except for the 1/8" thick parts, tap all holes coded yellow with a 10-32 tap. When you cut your circles, the tapped one and the circle center/untapped one need to be able to move through the plunger tube easily. The last circle should fit firmly in, but not too tightly.
Ignore the odd holes I drilled in some of the templates. I was testing out different sizes of plunger rods.
3) You'll need a scroll saw for this part. Feed the blade through the holes marked as squares and cut out along the line.
4) Before removing the paper from all of your parts, you'll need to mark the direction your parts need to face. With the template side facing up, turn all of the circles so that the dot is at the top. Now, mark all of the sides with an L (or other asymmetrical symbol). You can now remove the paper if you'd like.
5) Line up the tapped circle and the square center circle in the way they need to assemble and vice them. To the sides, drill and tap straight through them with a 5/32" bit and 6-32 tap.
6) Start feeding 1" 6-32 screws through the tapped circle until 1/2" is sticking out. Push the other circle onto the end and finish threading the screws through. Once you're done, it should look like this and measure 1" long total.
7) Take four threaded rods and screw four locknuts on until they are 5/8" from the end (5/8" gap, not including the body of the nut itself). Now thread rods through your circle-center, untapped hole, then through the square center and then into the threaded circle. Thread one up until the end is flush with the circle, and thread the rest so that a little more than 1/4" is sticking out.
8) Push your catch onto the end of the rods, followed by the washers. Line up the rod sticking out the most with its respective hole on the back plate. Rotate the back plate until it's tight against the other three rods. Rotate each of the other rods so that they thread into their respective holes. Make sure your catch moves smoothly and your loose plate slide along the rods nicely.
9) Now you'll make your plunger tube. It needs to be 10 5/16" long from 1.5" OD polycarbonate tube if you're using a 1 1/4" long bushing. If your bushing is shorter, make the tube shorter by the same amount, and vice versa. Goop/e-tape/o-ring or whatever you want to do, but seal the bushing to the end of the tube, and secure it in nicely. I used goop, e-tape and a 2" bolt through the entire thing, a la +bow.
10) This is a good time to mount your gun body onto a handle or larger shell. For this, I just used a maverick handle and corresponding trigger. You'll also need to tighten those locknuts down onto the catch as much as you can, while still letting the catch move freely.
11) From here, you need to attach the tube to the body. Move the sliding piece all the way to the catch and push the plunger tube all the way down onto it. Drill through the end of the plunger tube and into the sliding part with a 5/32" bit and tap the hole. Screw in a 1/4" length screw. Mark the plunger tube with the L. Don't worry about it breaking here, this part isn't load bearing. If you did it right, there should be a nice 5" gap.
12) Slide your tube assembly down the rods a little bit so that the spacer is in a comfortable angle for sliding. Drill, tap and insert three more holes and screws through the tube and into the spacer. It should now move very smoothly.
Caution: I'm pretty sure this video is nsfw. Pull out my dick have sex with your mom and everything.
13) Here you'll just want to make your plunger rod. The length for this should be 8 5/8" plus the distance from the back of the plunger tube to the back of the catch when the gun is collapsed. This should be about 1/2", making your length about 9 1/8". Cut your notch starting 3/8" from the end, and drill and tap the opposite end. Screw your plunger head between two 1/8" thick circles into there.
14) Cut your spring to any length between 7 1/8 and about 8" (the longer it is, the harder it is to prime, but the more powerful). Lube up your plunger tube, insert your plunger rod, notch up, then your spring. Push the body of the gun onto the back, and screw the spacer into the back of the plunger tube. It should be done now, bearing the tons of fine tuning you'll need to do.
If you didn't catch it, at the end of the video I mention how you can use this as a hamp-type mechanism for mercy kills. This system is pretty powerful, and I hope to see it adapted to many uses. It's certainly not the typical pump action method, but it sure works nice.
That should be everything. Enjoy.
Edited by Split, 06 June 2010 - 08:49 AM.