I knocked this thing out in less than 12 hours of solid work over 3 days, and completely out of stuff I had laying around. As far as tools I had a powersander, a powerdrill, and everything else was by hand. Its not a terribly hard project and if someone has scrap wood and likes to build things it can be a fun weekend.
Step 1: Planning and Materials
Step 2: The Handle
Step 3: The Barrel and Tumbler
Step 4: Appearance, Paint, and Patina
Step 5: The Grip
Step 6: Finishing
Step 1: Step 1: Planning and Materials
Scrap wood, 2x6 and some smaller pieces
pvc, 2 inch and 1/2 inch
Assorted hardware, pipe hangers, doorstop, decorative hooks, spring, brass pipe fittings, upholstery nails, screws and nails, random bits and bobs
Leather for the handle, or fabric, or felt, or whatever.
Paints and patina's
Brushes, preferably disposable foam, the urathane will ruin it
Glue, glue gun, and glue sticks
Step 2: Step 2: the Handle
Step 1: Transfer your sketch from paper to the wood you plan on using. For some people thats cut out the one on the paper and tape or glue it to the wood. For me that wasn't an option because I was trying to avoid a few huge knots in the wood so I just had to remeasure and redraw.
Step 2: Do some rough cuts. If you have a huge piece of wood knock it down to a more manageable size. From there take your coping saw, or a scroll saw, jig saw, band saw whatever you have and prefer, and get a blank of the gun, taking off the bigger chunks.
Step 3: This is actually slightly out of order, more of a step 2.5 Before I took too much wood off the blank I clamped the wood down and took the opportunity to drill the hole for the barrel before it got too weak in a few spots. I also too a file and widened the hole since the drill bit wasn't quite big enough to allow the pvc.
Step 4: Sanding. Probably my least favorite part and I did skimp on it a bit although its not really recommended. A lot of time and attention spent on this stage can result in an amazing final product. I'm just fairly impatient so I removed a lot of the tool marks from my files and saws and called it good enough. Also don't forget the other scrap. Its not required but I wanted something that looked a bit bigger, not to mention some additional support after I drilled the hole. Just make sure that you get the wood shaped to some extent before you glue it in place. It'll save time.
Step 5: Glue and clamp. If you have any other pieces of wood that you want to add for decoration or support now would be the time. Be liberal with the glue but try to avoid excess, or at least wipe up anything quickly as it will shield the wood from any stain or finish. Once you have the parts in place let it dry and cure and break out the sander again.
Step 6: While the gun is not functional and I can't even pull the trigger I did want the hammer to swing. I used a drill as it was all that I really had but just cut a channel that you can slide whatever you're using into and anchor it. I used a pin mounted doorstop because it had a pretty good shape and was laying around. Also, shiny brass.
Step 3: Step 3: the Barrel and Tumbler
Basically I took the two inch pvc and cut out the length I wanted the tumbler to be. From there I cut four lengths of the half inch pvc because thats what fit inside. I cut them a bit long, and arranged them inside, one edge flat, the other uneven and just started to secure them with hotglue. Once I had them all glued I took my trusty saw and trimmed them down flat.
The barrel was even easier, measure and cut.
Step 4: Step 4: Appearence, Paint, and Patina
Pvc. Most people will paint this. There is nothing wrong with that. However I have an alternative I am absolutely in love with. I now share with Instructables the treatment that once got me asked if I was using welds when I had nothing more than pvc and epoxy. Foil tape. Its distinctly metallic, not like a silver paint which is just a little shiny. In addition to that it doesn't have a perfect finish, little folds and wrinkles here and there make it easy to look aged. Just dry brush some black paint and while it won't like to stick to smooth parts of the tape it will cling to these wrinkles and seams, simulating grime gathering in similar scratches and dents. Pair that with hot glue or epoxy and you get bubbly effects that simulate welds very well.
Now those copper bits I mentioned. I had half ring pipe mounts but I'm also known to use the long pipe hanging straps. I treat both of these the same way. Crank the grill up on high and toss them in. Wrapping them in foil will protect the finish so only the color warps a bit in the heat. Straight in the fire and they get scorched and blackened, making it look very dirty and well worn.