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[superwoodle]

Hi, everyone! I’m new to the forums and Airsoft.

 
I am currently building an Airsoft AEG modeled after a picture of a concept Hk G38. Using solid works I have almost completely designed the gun out of sheet metal. I have already reached my budget which was a low $100.


This build will include
-Complete 5052 Aluminum water-jet cut sheet metal body
-Stock Version 6 gearbox, to be upgraded
-Stock CYMA M14 barrel and (modified) hop up
-Any cap m4/16 mags
-8.6v battery
- 3 five inch weaver rails and 1 eight inch rail
-Semi and fully auto selector similar to an AUG
-weight of around 10lbs and a complete length of 32.5 inches

PIC HEAVY!!

Concept picture
UPDATE 7/17/10



This starts the official build

UPDATE 5/25/10
Guess what came in the mail!



An aluminum tube!

My outer barrel


UPDATE5/15/10
Just my band saw to some metal in the garage to make up a quick mag release and check my math and leverage. It’s decently hard to depress, so I don’t think my mags will fall out.


The screw in the middle is the fulcrum and is conection to the gun (in this case the vice). The piece of aluminum is not actually connected to the center screw, only through the piece of spring steel.


In locked position, (the nut on the right representing the tab, that would normally hold the mag in place).


In pressed position, the mag now free (sorry for the glare).








UPDATE 5/13/10

Without “Gap”

UPDATE 5/4/10



How would I apply/make markings or decals?

Questions, comments, suggestions? Ask away!
- Woodle

[JohnnyChrist]

If by "Firing control unit" you mean a MOSFET, then do that, it would probably be much simpler.

Anyways, that gun is beautiful, it reminds me of one of my SMGs from Borderlands, just paint it a bright red and put an Eotech on it and its the same weapon.

EDIT: Just googled it, its from Halo.

I was hoping its actually a real gun, that'd be sick.

[Ghillie Man]

You could probably construct this firearm from a L85

[MetallicaFatCat]

That or an AUG, which is what I would do.

[superwoodle]

You could probably construct this firearm from a L85

You could probably construct this firearm from a L85

Um im building it from scratch, ie. sheet metal.

If by "Firing control unit" you mean a MOSFET, then do that, it would probably be much simpler.

Anyways, that gun is beautiful, it reminds me of one of my SMGs from Borderlands, just paint it a bright red and put an Eotech on it and its the same weapon.

Yes, but I’m trying to find one that only has semi or full auto, do you know of any, other than those fancy programmable units that are really expensive?

[mario1286]

You're going to need a lot more than just sheet metal to build a functioning airsoft gun.

What kind of metal are you planning on using?  How are you going to do the plastic parts like the pistol grip and such?  I'd start looking at existing weapon systems first, then fabricate the non-airsoft existing ones.

A Famas would work as well, but as we all know it has that V1 gearbox and proprietary motor.  Maybe it'd be possible to salvage parts from one.

[superwoodle]

You're going to need a lot more than just sheet metal to build a functioning airsoft gun.

What kind of metal are you planning on using?  How are you going to do the plastic parts like the pistol grip and such?  I'd start looking at existing weapon systems first, then fabricate the non-airsoft existing ones.

A Famas would work as well, but as we all know it has that V1 gearbox and proprietary motor.  Maybe it'd be possible to salvage parts from one.

I’m going to use 6061 Aluminum. For plastic, there will be none. Just hard rubber for the butt pad and foam handle padding. If you have seen or heard of a +bow, then that’s how my handle will be built.

[dune titan]

Your source pictures are of two completely different guns. Are you going with one or the other, or a mix?

Do you have a 3d computer model that you can get dimensions from? I don't see one on the sketchup warehouse.

First, I would get all the internals you need. If this is going to be an aeg-based setup, then you need a fully functioning self-contained gearbox (v2 will not work unless you incorporate the pistol grip into your design), a hop-up unit w/ barrel, and a battery. Once you have all these, figure out where the geometry of your G36 concept model intersects with the geometry of the internal components. These will become your connections points, to hold the internals to the externals. Then, you need to figure out where you want a slide/hole to be so you can access the adjustment wheel on your hop-up. You also need to figure out how to build a working magazine catch. Also, you need to find out the thickness properties of whatever your going to use for the pistol grip and buttstock so on you can machine scaled-down copies for your body.

I would build two models: The first would be a box, with some crude cuts to give it the basic shape of the gun. On this first model you would work out where and how the internals would work and go, and once finalized, begin the second model. I would make this model again a box, if not a little more complicated that the last, and then take away and add material until it is how you like it.

As for the locations of the internals: A v6 gearbox pushed all the way to the back coupled with a m14 hop-up unit that has a feeding-tube extension to reach down the the magazine would work. Battery placement would probably be in the handguard.

Remember: If your serious about your project, start small and get a hang of the materials. If you don't own an aeg, make sure you at least mess around with one so you can see the complications you haven't thought of yet. I'm not saying it's impossible, but make sure you have a full perspective and there are no 'I'll figure it out when I get to it' parts.

Hope this helped,

~Dune

[superwoodle]

Your source pictures are of two completely different guns. Are you going with one or the other, or a mix?

Do you have a 3d computer model that you can get dimensions from? I don't see one on the sketchup warehouse.

First, I would get all the internals you need. If this is going to be an aeg-based setup, then you need a fully functioning self-contained gearbox (v2 will not work unless you incorporate the pistol grip into your design), a hop-up unit w/ barrel, and a battery. Once you have all these, figure out where the geometry of your G36 concept model intersects with the geometry of the internal components. These will become your connections points, to hold the internals to the externals. Then, you need to figure out where you want a slide/hole to be so you can access the adjustment wheel on your hop-up. You also need to figure out how to build a working magazine catch. Also, you need to find out the thickness properties of whatever your going to use for the pistol grip and buttstock so on you can machine scaled-down copies for your body.

I would build two models: The first would be a box, with some crude cuts to give it the basic shape of the gun. On this first model you would work out where and how the internals would work and go, and once finalized, begin the second model. I would make this model again a box, if not a little more complicated that the last, and then take away and add material until it is how you like it.

As for the locations of the internals: A v6 gearbox pushed all the way to the back coupled with a m14 hop-up unit that has a feeding-tube extension to reach down the the magazine would work. Battery placement would probably be in the handguard.

Remember: If your serious about your project, start small and get a hang of the materials. If you don't own an aeg, make sure you at least mess around with one so you can see the complications you haven't thought of yet. I'm not saying it's impossible, but make sure you have a full perspective and there are no 'I'll figure it out when I get to it' parts.

Hope this helped,

~Dune

There is only 1 source picture. All except the first picture are screen shots from solid works of my actual 3D drawing. I took the original picture and scaled it, making cardboard mock cut outs until I felt satisfied with the feel and size. You nailed %100 the internal set up I’m currently planned for. I have a mag catch designed, but I’m going to build and make a test catch, to make sure it works.
 My only issue is finding a way to make a handle. I intended to sandwich a rubber or foam pad between 2 plates.
   I CAN’T get parts machined. My only option for this was cutting parts on a water jet. Although I could hand make parts by hand.
I hope to hear from you some more you have been very helpful.
Thanks very much!

[dune titan]

 My only issue is finding a way to make a handle. I intended to sandwich a rubber or foam pad between 2 plates.

I would make a wooden core for the pistol grip that's 5-10mm thinner than the desired finished product - using wood because it's easier to shape for more ergonomic applications. Anyway, on top of that take some kind of epoxy or putty, and while wearing latex gloves shape it around the wood grip until you have the desired effect. Search around the gallery, someone has a AK47 with a custom enlarged pistol grip using epoxy. I'll post back if I happen to stumble upon it.

Also: This place occasionally sells long lengths of cheaps RIS that you can cut to size for your application: http://stores.ebay.com/EGW1__W0QQ_sacatZEGW1QQ_sidZ4033613QQ_trksidZp4634Q2ec0Q2em14?_pgn=1

Also: If you don't have a pair of calipers, get some. It looks like you're good at CAD work, and you can save yourself a headache by pre-designing everything in the computer.

~Dune

Edit: Dangit I need to stop switching from forum to forum, I signed as 'Ecko' instead of 'Dune' lol.

[superwoodle]

I would make a wooden core for the pistol grip that's 5-10mm thinner than the desired finished product - using wood because it's easier to shape for more ergonomic applications. Anyway, on top of that take some kind of epoxy or putty, and while wearing latex gloves shape it around the wood grip until you have the desired effect. Search around the gallery, someone has a AK47 with a custom enlarged pistol grip using epoxy. I'll post back if I happen to stumble upon it.

Also: This place occasionally sells long lengths of cheaps RIS that you can cut to size for your application: http://stores.ebay.com/EGW1__W0QQ_sacatZEGW1QQ_sidZ4033613QQ_trksidZp4634Q2ec0Q2em14?_pgn=1

Also: If you don't have a pair of calipers, get some. It looks like you're good at CAD work, and you can save yourself a headache by pre-designing everything in the computer.

~Dune

Edit: Dangit I need to stop switching from forum to forum, I signed as 'Ecko' instead of 'Dune' lol.

What if I were to fiber glass or carbon fiber a block of hard foam or wood, sand and paint? Would that work?
Thanks again

[dune titan]

What if I were to fiber glass or carbon fiber a block of hard foam or wood, sand and paint? Would that work?
Thanks again

Fiber glass would be a pain, carbon fiber I'm not sure. In the end you'd have a 'solid' feel with no tactile grip, so I would use any materials as long as the end result is the same, and then throw on a coat of truck bed liner spray. That will give it some grip.

What are you going to do for the barrel? If your going to build everything from scratch except the internals, you might as well do it right. Find a thick section of pipe with an inner diameter closest to the outer diameter of your inner barrel, and then fill in the gap with melted wax. That way, you'll have a solid barrel that will absorb the vibrations.

If this is turning into a conversation between me and you, we might as well take this to a PM as to not spam the forums.

~Dune

[9Battousai]

For a more solid barrel mounting option, you could go with low temp alloy ( http://en.wikipedia.org/wiki/Wood's_metal ) since it melts at 158F and doesn't like bending while it's a solid.

It's kinda heavy, but an excellent 100% solid-mount option. Just melt it into the area you want, and you can remove it using boiling water.

[Grim09]

Funny, I found the stock image a couple weeks ago and was half-planning how to go about making it. I'd love to help with the design aspect of it. I'm just not that good with knowing materials, yet. (As a side note I was playing with the idea of just using a PSG-1 grip with some material wrapping around it like in the stock pic. Then I looked at available grips and prices, and that idea went out the window. )

For the bolt handle for your particular model, you could go with the easy to implement AK style, with the handle just stuck on the bolt. Or if you wanted a bit of a challenge you could try experimenting with something like a Famas charging handle, most likely in between your rail and cheek rest. Though it would probably have to be shorter than usual so that it wouldn't interfere with your line of sight. Course you could also go crazy and make it a iron sight and charging handle combo. Just thinking out loud.

Maybe you would want to also consider using VN style mags? They really look good in the stock image as opposed to regular mags.

Finally, have you thought about making a longer fore grip along with the standard sized one? You could use the longer for a more DMR "configuration" look, though a longer barrel would have to go in as well.

Best of luck!

[superwoodle]

Funny, I found the stock image a couple weeks ago and was half-planning how to go about making it. I'd love to help with the design aspect of it. I'm just not that good with knowing materials, yet. (As a side note I was playing with the idea of just using a PSG-1 grip with some material wrapping around it like in the stock pic. Then I looked at available grips and prices, and that idea went out the window. )

For the bolt handle for your particular model, you could go with the easy to implement AK style, with the handle just stuck on the bolt. Or if you wanted a bit of a challenge you could try experimenting with something like a Famas charging handle, most likely in between your rail and cheek rest. Though it would probably have to be shorter than usual so that it wouldn't interfere with your line of sight. Course you could also go crazy and make it a iron sight and charging handle combo. Just thinking out loud.

Maybe you would want to also consider using VN style mags? They really look good in the stock image as opposed to regular mags.

Finally, have you thought about making a longer fore grip along with the standard sized one? You could use the longer for a more DMR "configuration" look, though a longer barrel would have to go in as well.

Best of luck!

What do you meen when you say AK style?

[JohnnyChrist]

What do you meen when you say AK style?

Having the charging handle attached to the bolt.

[cpt. pupdum]

I’m going to use 6061 Aluminum. For plastic, there will be none. Just hard rubber for the butt pad and foam handle padding. If you have seen or heard of a +bow, then that’s how my handle will be built.

a fellow nerfer!!!

[superwoodle]

EDIT: Just googled it, its from Halo.

I was hoping its actually a real gun, that'd be sick.

Damn, I thought it was real too. o well

[DTRSandman]

I say in the front lower receiver add a madbull eglm as an integrated GL.

[superwoodle]

I say in the front lower receiver add a madbull eglm as an integrated GL.

I was thinking about that, only I don't have $200 to spare.

[DTRSandman]

I think if you're going homemade custom splurge a little bit but that's just me.

[Nixons Back]

Here is a website if you need some custom parts made. You can get custom plastic or metal parts machined, and things like that. Should make building this a little easier for you.
http://www.emachineshop.com/

[superwoodle]

!!!Desing and parts are being sent in this week!!! If you got any ideas, speak now or forever my gun will be.

[Gooberz]

Why is there a gap in the middle of the gun, above the trigger?

[superwoodle]

Why is there a gap in the middle of the gun, above the trigger?

Why not? Looks cool and would just add weight to cover it.