Introduction: Han Solo Blaster

Picture of Han Solo Blaster

In this tutorial I'll teach you how to make a pretty good Han Solo blaster replica using a children's toy to start with.

Materials Needed:

Han Solo toy blaster
Drill bit (1/16 inch)
"Hole saw" drill bit (about 1/2 inch)
Paint (black/silver/brown)
Painters or masking tape

Step 1: Get Your Gun

Picture of Get Your Gun

I am making this Han Solo blaster for my Halloween costume. For that reason I want it to look real but it doesn't need to pass for an authentic movie replica. There are a lot of options online but I found the cheapest option to be the Han Solo toy blaster.

I ordered mine from Wal-Mart and they shipped it to my local store for free. I was worried it would be smaller, like for children's hands, but it was actually a great size, probably even the same as the movie version.

Step 2: Preparing the Barrel

Picture of Preparing the Barrel

The gun is bright orange and white, hardly realistic. On top of that, where the holes should be on the barrel, they are instead only indentation marks. To make this gun look more real I took a 1/16" drill bit and drilled out the holes along the outside of the barrel. This goes really quick since its thin plastic.

The front of the barrel (where the shot should come out of) is also covered. For this I had some "hole saw" bits lying around and found one that was about 1/2" wide which was a pretty good fit. I carefully drilled out the front of the barrel. When I did this the barrel came off and I thought I broke it, but then I realized it is made to. Probably would have been easier to pull it off in the first place before I drilled it out.

There were a few parts on the front of the barrel that the hole saw bit didn't quite get so I used a pair of pliers to just break off the extra plastic that was left.

Step 3: Painting Black

Picture of Painting Black

Now the gun is ready for the first coat of paint. I used black spray paint that also had primer in it to make sure it stuck to the plastic. I did this outside on a breezy day and it dried in just a few minutes so I was able to do both sides very quickly.

The first coat with primer had a flat finish and I wanted the gun to have a more polished metal look, so I then did another layer with black gloss spray paint. You can see in the picture how it has more of a shine to it.

Step 4: Painting Silver

Picture of Painting Silver

There are multiple versions of Han Solo's blaster depending on what movie you are referring to but I was going for Han's blaster in The Empire Strikes Back.

I taped off the barrel with some basic masking tape I had. I made sure to attach it to my shirt or pants first to get rid of most of the stickiness (you don't want the tape to pull of your paint). According to my reference image, the silver should be on the cone shaped part of the barrel and the bigger part which bridges it to the main body of the gun. Any silver paint would probably do but I happened to have some that had a "hammered" look that we used for a previous project.

I sprayed the barrel from multiple angles and then let it dry.

Next, I used a piece of notebook paper and taped it into a funnel shape. I slowly cut off the tip of the paper until the resulting hole was the same size as one of the main bolt looking things on the plastic. I put the paper over the part and sprayed silver into the hole. This method was much quicker than trying to tape off the whole gun.

Step 5: Painting the Grip

Picture of Painting the Grip

Finally, I taped off the handle following the basic contours of the mold and painted it brown. If I had brown spray paint I would have used it but since I didn't I instead used acrylic paint.

Step 6: Finishing the Blaster

Picture of Finishing the Blaster

I wanted the gun to have a used and weathered look so I got out my black spray paint again and did some light spraying on the barrel to make it look used. I sprayed inside the barrel as well as on the outside, making sure it was darkest near the tip of the barrel and tapered off further down the barrel.

Besides looking quite authentic, this altogether only took me maybe 30 minutes of work (apart from letting the paint dry). Since I didn't have to buy anything besides the gun itself I ended up with a real looking Han Solo blaster for under $15.


Hans-A-Zarkov-Jr (author)2017-11-04

Very nice job! Well done, that man!

JürgenB3 (author)2015-10-25

im gonna do it :D

ryanhaldy (author)JürgenB32016-08-06

Did you end up doing it with the glass? Would love to see it.

ChristinaR56 (author)2016-08-02

Where did you buy the toy gun?

ryanhaldy (author)ChristinaR562016-08-06

I got mine at

SebastianT52 (author)2016-08-06

Thanks for the tutorial. For a better look remember to sand those hasbro letters from both sides of the gun.

JediMasterG (author)2016-01-10

Very nice. Great job. I'll have to try this.

JediMasterG (author)2016-01-10

Very nice. Great job. I'll have to try this.

JürgenB3 (author)2015-10-30

I wonder if I could actually, make holes, put some kind of round glass maybe and make the scope look like a real scope..

Bwilson Props (author)2014-10-31

hey, i built my own one too, it's great what you can do with such cheap materials!..

erik.olson.5661 (author)2014-10-13

Good work thanks! Will post my results based on your great Instructable!

ryanhaldy (author)2013-11-20

Figured I should show everyone why I made the blaster. I definitely wasn't trying to make a movie replica, but I think my costume turned out pretty well. Not to mention that my wife came along with me as 'Hoth' Leia.

SonicLoverSeth (author)2013-10-20

Awesome job!! Looks great!

mntbkrguy (author)2013-10-17

That is so cool I love star wars!

Phobanthropic (author)2013-10-16

You can just spray a small amount on a piece of paper and use a paintbrush for the "bolt looking things". Takes about 10 seconds and you don't have to worry about the funnel leaking.

dad_a_monk (author)2013-10-15

Most people don't have the law right about fake guns having to have an orange tip. Only when a replica or toy gun is SOLD does it have to have an orange tipped barrel. Once you own it there is no violation to reverse or cover the safety coating. The law goes back to a kid killed in LA by a police officer when the kid jumped out of bushes with the old black laser tag guns in the 80s. Obvisoully the gun was not a real shape of a gun but it was dusk and the officer took it as a real weapon. So the choice to keep the orange tip is a personal not legal choice. and I agree I would never have a blaster with an orange tip. Defeats the purpose of the prop. This is a GREAT guide. Big Star Wars fan!

boomshakalacka12 (author)2013-10-15

Instead of using rub and buff you can put paint on a paper towel it's basically the same thing

vigothecarpathian (author)2013-10-15

Nice! Title picture reminds me of the cover of the first Foo Fighters Album.

Haha I didn't even think of that but it does! I remember when that album came out and I wondered if it was a picture of Han's blaster.

foehn (author)2013-10-15

What a great job! And all done with paint, very easy. Years ago, friends and I made a blaster from the first Star Wars movie, for a friend's Han Solo costume. We pieced it together with bits and pieces of stuff from other things and hand carved some of it. But yours, yours is explictly explained and looks easier to do--with that toy base to start. You are inspiring me to make one, just for the hail of it. 'Cuz I want one!

ryanhaldy (author)foehn2013-10-15

Thanks for the compliments. It's a complicated enough shape that to spend $13 on the gun and then only have to add paint was TOTALLY worth it for me as opposed to trying to make the gun from wood, metal, or something else.

jberry4 (author)2013-10-15

Awesome. Would have been made even more realistic substituting the silver paint with silver rub n buff. :)

Infinitevortex (author)2013-10-14

Looks very nice!

thematthatter (author)2013-10-14

For safety reasons i would have left the tip orange. You never know when your having a drink at your favorite Cantina on Tatooine when someone decides to shoot you.

SWV1787 (author)thematthatter2013-10-14

Or you could just do like Han and shoot first

ryanhaldy (author)thematthatter2013-10-14

Ya, the packaging on the gun even says, "Do not modify this gun to look real blah blah blah." The whole point though is to make this gun look real! Who wants an orange tipped DL-44 heavy blaster pistol? Not me!

I think the best advice, just don't walk around pointing it at people, especially if you're not at a Halloween party.

About This Instructable




Bio: I mostly work in the media realm but I love working on hobby projects when I get a chance.
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