Schwaggy

The purpose of the experiment was not using metal OR adhesive. In case you haven't been browsing the dartmaking sections, there has been a push to find a "safe" dart not using metal or hot glue. Yes, hot glue works for most purposes (aka almost all my dart), but I think you're missing the point.

Forgive me if I'm being ignorant, but how much negative impact can a tiny dab between the foam and the button(s) be? I wouldn't think it would make any noticeable difference if a dab of hot glue was sandwiched between the pieces.

Interesting, I think it's because I might be using high temp glue sticks or you're using low temp glue sticks because live in california were it's always sunny.
Anyhow high temp hot glue might provoke the problem.
you might find some here www.glu-stix.com

I live in Arizona and it's ~115 degrees, never had a problem.

because that would be very time consuming and inconsistant.

As opposed to this very quick process? Props for experimenting and trying something else but I cant see why you didn't just use hot glue. I tried the other day to sew a button onto a piece of FBR and I could make 5 with hot glue in the time it takes to make one of these.

I wouldn't doubt ranges of 90 feet if fired with a slight angle. I was hitting 50 (or more with a perfect shot) PTG when stock.

Personally, the majority of my wars are indoors. My house is fairly large but the floor plan makes for close quarter battles most of the time. A few areas require a somewhat longer range but this can simply be solved by sprinting for a second to get a bit closer. In my scenario, we primarily play with stock (a few are basic AR removal/slightly upgraded spring), simply because we have no need to shoot 100'. The N-Strike series blasters are the clear choice. Give me my AT and a Recon, one on my back, and 1. You are not going to beat my ROF unless using a Nitron (which sucks IMO due to the delay between trigger pull and firing) and 2. You will never out gun me because I have four 18 round drums on me...

With all of that being said, when we play outdoors ranges of ~50' are entirely possible. For something like this the Vortex series really shine, unless, as I stated earlier a breeze or anything of the sort picks up. Even in this outdoor battle, the pro's for N-strike I outlined earlier are still in full effect; Faster ROF and much more ammunition. We aren't playing the "hide behind the bunkers on either end of the yard and take hail marys at the opposition" game though so extra range, while nice to have, isn't going to make or break much if anything at all.

Game type, environment, and personal play style are what will really determine which series of blaster work for you.

The vortex line is cool but honestly I still prefer my clip fed blasters and other streamline blasters more. The disks, when outdoors, get thrown off direction by the tiniest breeze. Indoors, the disks bounce off everything and can sometimes be very tough to find. This, of course, is no good when comparing the cost of the two options.