Often concept art doesn't make it into the games or films they are designed for. Borderlands, while proudly baring its loose and comic book-esque style, still has to dumb-down certain parts of their designs for them to fit into a restrictive game engine. For this reason, I decided to base my prop directly from the concept art which the standard in-game Dahl assault rifle was from. Doing this gave me some artistic freedom too, since the reference pictures I could scavenge were far from all-encompassing and I prefer to tweak my creations according to the things I can recycle.
This project turned out really well and was a thoroughly enjoyable build. In total I spent somewhere in the region of 300 hours on the build, although if I had made fewer mistakes and done certain parts more efficiently, this time could be reduced to under 100 hours. The cost for me was around £120, the main expense being the paint followed by the sight. Bearing in mind I work in such a way so as to favour using things I already have rather than buying new things, someone who has less materials or tools than me could spend well over £250.
I don't expect anyone to read this instructable from beginning to end, but I hope that people interested in prop-making or similar will find some of my methods resourceful.
Most of this stuff I already had, and assuming you've done similar projects before (Or just have a well-stocked shed) you are likely to have it lying around too. In total I didn't spend a great deal on this project, but buying all the materials could set you back around £250 or more. I also used very few electric tools for this build. Also, not working with a mask on when sanding, spraying or using MDF does not make you tough, it makes you get ill and have black earwax (Speaking from experience). Also, its important to wear eye protection particularly if you using a Dremel, because if you use a cheap one like me the attachments have a habit of exploding in your face.
• MDF/Plywood relatively thin, around 3cm thick, and an even thinner one at about 1cm
• Flexible plastic sheeting - I'm not sure of the exact material I used but it cut well with a knife and was slightly flexible, you could just use even thinner MDF though
• Acrylic sheet
• Plenty of filler
• Whatever nuts, bolts and fittings you can salvage
• Super Glue
• Panel pins
• Sculpting putty
• Various bits and bobs for detail
• Something for the barrel - I used handlebars from a micro-scooter but you could use PVC tubing or anything else that will do the job
• PVA glue
• Jig-saw and/or Scroll-saw
• Various Files - Flat and rounded
• Lots of sandpaper in various grades
• Stanley knife - With spare blades, because its going to get blunt
• Surform - Not essential, but useful
• Small hammer
• Dremel - Not totally essential but you should probably have one anyway, they are incredibly useful
ANY tool that makes sanding less painful - I had an old orbital sander, but I would really have liked to use a belt sander
• Breathing mask
• Eye protection
• Old clothes - No matter how careful you think you are, filler will ruin anything within a 2-metre radius of itself