A while back I picked up a handful of surplus Vietnam-era synthetic stocks (1 nice one, 2 thrashed ones) with the idea of using them as a starting point, and after some experimentation, came up with a technique that I think is worth sharing. Depending on what materials are used, a nice stock can be built for as little as $150-$200. In this Instructable, I'll show a technique that I used to build 3 variations of a comfortable and functional stock.
What you will need:
- Donor stock - this can be a nice one, but it's better to use a structurally sound "less pretty" one as the nice synthetics are becoming harder to find - and the less "aesthetically pleasing" ones are a lot less expensive. Expect to pay around $20-30 for a solid candidate.
- A pistol-grip style buttstock. I've found the aftermarket stocks for the Mossberg 500 series shotgun seem to work well and have about the right shape as well as a good "keying" surface.
- Epoxy - I use a quality 30-minute epoxy. I find the faster-setting epoxies don't seem as strong and don't seem to bond as well - just my opinion, of course.
- A Tee-Nut that matches the buttstock mounting bolt you intend to use. 5/16" X18 X 7/8" in this case. I used the 3-hole version, not the barbed version of the tee-nut.
- Hot glue gun
- Fiberglass cloth or chopped fiberglass
- Petroleum Jelly to act as a parting compound or release agent
- A sculptable epoxy clay or similar (possibly fiber-filled bondo, but I like to use similar materials for better bonding)
- Paint - Duracoat in my case, but rattle-can paint would work, too.
- An electric handpiece, Foredom, or Dremel would be very helpful
- Various files, sandpaper (wet/dry aluminum oxide), clamps, hacksaw or sawzall, sander, etc