Forward: This was a project I designed during my last semester at school. It was an open studio project, so I chose to make a mock line for the Nerf brand. It essentially exists as a line to bring the casual nerfers and makers of the community together. This CAD model has taken me more than 150 hours of work to get to this point. Definitely been my biggest project I've taken on yet! Here's some of the details.
Edit: Now with less crunchy images!
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Here's an animation of the transition between the Standard Kit to the Bullpup kit.
The Kit utilizes internals stolen from a Retaliator/ Recon Mk II outside of a new plunger rod, trigger, and mag release. I utilized brass threaded inserts and thumb screws to attach different sections of the blaster together. These can be purchased at McMaster-Carr
Brass Heat-Set Inserts For Plastic, 6-32 Thread Size, 0.150" Installed Length : 94459A280
Knurled-Head Thumb Screw
Slotted, Stainless Steel Low-Profile, 6-32 Thread, 1/2" Long : 91746A644
The parts themselves are fastened with nuts that were superglued into place and bolts that were cut down in most places to fit flush:
Passivated 18-8 Stainless Steel Pan Head Phillips Screw, 4-40 Thread Size, 2-1/4" Long : 91772A517
Low-Strength Steel Hex Nut Zinc-Plated, 4-40 Thread Size : 90480A005
Finally, the parts themselves are available at Thingiverse for download/printing. Would love get feedback/see what people do with this project, whether it's via printing it themselves or remixing it. I've got the STEP file on Thingiverse.