Siarnaq

I love the syringe idea. Does it get sticky after a while from having all that silicone injected into it, or is that not an issue? You could probably use it with oogoo as well, which would solve the annoyance of squeezing it into the darts via a plastic baggie.
These look pretty similar to Kane's original rubber darts, and the main issue with them is that they don't feed in hoppers. Too much friction from the silicone tip. I imagine yours have the same problem, but I figured I'd ask anyway. Or, wait, do you have any actual wyes? From your posts it looks like just homemade ones. Then again, it'd be interesting to see if there were any homemade wyes that they did feed in...

How deep / what size are your holes? I doubt that silicone caulking varies in density by more than 10%. Also, did you pick out any chunks of foam that stayed in your hole? Did you miss volume by leaving a bubble at the bottom, or by not filling to the brim?

All of the above problems, on different darts. I don't think I got one good one out of the batch. The silicone I used flowed super uncontrollably. Not sure why. Maybe I'll try and find some of that polyeurethane stuff. My holes are almost exactly 1cm deep.

I'm also finding that my length is unusually critical. For ease of production, the blanks are all 40mm, but the darts don't feed at 40mm in my PAC--They must be cut down to about 32mm, then they work just fine. Normally I don't think that length would have been a problem, even with my fairly rigid foam.

I'll start using that length, I guess. Since you cut them down after they're completed, do you cut the entire dart to that length, or just the foam itself?

I'm curious what weight your slugs and VANS are. Mine are about the same weight (.8g ish)

My VANS were like 0.5g, at most. I'll go measure a slug in a few minutes, but I'm pretty sure the VANS were way lighter.
(EDIT: Yep, my slugs were 0.8g.)
Granted, I didn't get enough silicone in them, but I wouldn't think what I missed would make that much of a difference. Maybe it's cause I was using the kind of silicone used to make oogoo(GE 1?), so that I could try that out as well. I don't think that'd make a difference, though.

I still think that it is a good tradeoff for having ammo that is not embarrassing to show people from outside the hobby.

Yeah, pretty much.

The tube was actually a disposable icing bag - picture a wedge shaped Ziploc bag, fill it with the silicone caulk and a level spoon ful of corn starch, twist the back of the bag, to lock the contents in and kneed till mixed, then clip the tip and twist more to put the contents in the bag under pressure so only a little added pressure squeezes out the oogoo. The fine tip really helps to fill from the bottom of the hole up to avoid air bubbles. Twist the back of the bag as needed to keep the pressure up.

I just wish they performed better. In retrospect the filling process could of forced out the thin retaining wall of the fbr, giving a tighter than normal dart fit - and my crappy ranges. Perhaps a gentle squeeze to the uncured tip would be more beneficial than a bb.

When I made my batch, I actually tried a few with oogoo, but found it too annoying to squeeze out of the bag. Maybe I'll try those. As to your performance problem, are you sure it wasn't a problem with the weight of the darts? That was my main problem. Even though I didn't really get enough silicone in any of mine, I can't imagine that the little air bubble at the bottom could double the weight to 0.8g. Maybe the scale I was using was off. Or maybe I just need to drill deeper.

One point of confusion though - they are "definitely called VANS", unless they are on Nrev - where they are "definitely called BANS"... Is there any hope of gaining some consistency between the two sites - least they start being referred to as -ANS?

Dunno what you mean, they're definitely VANS. Kane said so.

Maybe I am wrong, but doesn't it seem like these blasters, more so the homemades, are starting to get to the power of some of the airsoft pistols?

Actually, if I remember right, our blasters are way more powerful than most airsoft guns, but our ammo is less efficient.