Introduction: How to Make a Portal Gun.

This is how i made my portal gun for halloween 2011.

it is one of many way that you can make a portal gun. i made it this way because my experiances with these materials were higher than any other method. 

Ive entered this to the Hurricane Lasers Contest, if you like it enough could you please vote for me at the top of this page.. Thank you in advance. :D

Step 1: Materials

Blue insulation foam for the main shells of the gun.

the barrel and body were made from PVC pipes at 110mm and 70mm  and one clear 65mm tube. also a solid clear acrylic rod at 20mm

plastic acrylic sheet for detailing parts.

three black cables (thick electrical cable is fine) and wire to put inside.  or three wire core foam wrapping strips (like the hair curling things. i found mind at a general store or DIY store)

for the electronics i had two bright blue LEDs and two red LEDs (shoud be orange but i didnt have any) a three way switch, an assortment of wire and a 9volt battery.

emulsion paint, filler primer spray paint, plastic primer spray paint, lots of white spray paint and black spray paint.

car body filler (most commonly called bondo) i used P38 polyester filler.

Glue! lots of glue ranging from two part epoxie and super glue.

also masking tape.

Step 2: Tools.

the tools used for this project were:

belt sander, jigsaw, hacksaw blade and lots of craft knifes.

losts of different grade sand paper: corse to very fine.

soldering iron for the wiring.

lots of clamps.

Step 3: Shaping the Two Shells.

stick the layers of blue insulation foam together and draw on the out line of the shells.

Then roughly cut out the side profile then the top.

Then use a belt sander to bring the blue foam closer to the shape of the back and front shell.

then draw a thickness of the shell and carve out the inside of the shell to hold the rest of the gun.

then paint the shell with the white emulsion to seal the foam from the filler and the paint which will eat the foam if not sealed.

Step 4: Barrel

cut two rings out of the acrylic to create supports for the smaller PVC tube with in the larger.

then trace the cut out shape on to the larger tube and cut it out.

place the smaller tube inside using the ring supports, making sure there is enough of th smaller tube out front of the larger to create the barrel of the gun.

then trace the same shape on to the smaller one and cut it out, matching up the cut outs.

glue it all together.

add a PVC coupler to the rear for the handle.

fill the gap between the two tubes and sand it all smooth. then carve in the vent shape at top front of the opening of the hole.

Step 5: Barrel

place a hook connector made out of acrylic on the top of the fron barrel section.

spray the plastic barrel with plastic primer then normal primer to get a uniformed finish and sand down lumps and uneven sections.

do the same with the front and rear shells. if there are any uneven sections/ dents in the parts fill and sand again untill you get to the finish you want.

test fit the barrel in the two shells to make sure it all fits together.

cut out and construct the claws out of acrylic.

tyhe last pic shows me showing the claw for size comparrison.

Step 6: Barrel

cut out three rings for the barrel end.

first ring is a larger thicker ring for the rear of the barrel. chamfer one side to the thickness of the second ring.  (see photos)
the second and third rings are the same size but the third is chamfered to the front of the barrel.

paint and fill to make them smooth and space them evenly on the extended barrel (smaller tube inside larger barrel)

then paint the whole lot with black spray paint. i used matt but it can be gloss.

Step 7: Finishing the Shells.

spray the shells with filler primer and sand them to a smooth finish.

insert two hook mounting points into the front shell.

add the three small wire emmiter points onto the rear shell. the emmiter points were made in the same was the shells were.

spray them both flat white.

then add some decals for the portal branding. this can either be done in hand painted through a stencil or cut out of vinyl stickers.

then spray a gloss coat over all the shell and logos to give it a great shine and to seal the decals.

Step 8: Lighting.

wire the LEDs and resistors to the three wat switch with the top position being blue the middle being off and the bottom being the orange.  

when all has been connected wire the battery socket and the lighting system is done.

take the solid 29mm acrylic bar and sand with a rough paper to make a diffuser. this is what the light will be placed at the end of to give the glowing portal chamber.

inside the clear 65mm tube the light bar is held by two more acrylic discs and on them are some detailing (in the pictures i have used two large format printer spool ends.) but use whatever you have to hand.

wrap a small amount of tape (preferably black) around the clear tube with the light bar inside at the end points where the support discs are. make sure the discs are wide enough apart that when in the main gun tube they are just inside the tubes and not visible.

Step 9: Assembly.

place the clear tube assembly inside the main barrel of the gun and glue it in.

glue the LEDs onto the rear of the diffuser and affix the switch somewhere inside the handle assembly where it will be easily reached by your thumb when holding the gun.

glue the front shell the the barrel assembly so the peak of the front shell is at the same level of the front barrel.

drill two holes behind the hook mounting points. into which glue the wires.
on the top of the barrel behind the hook mounting point drill a hole for the wire.

in the wire emitter points on the back shell drill holes where the wires will be placed.

glue the back shell onto the rear of the gun and drill down through the top hole in the rear shell. (20mm) for another section of the solid bar to be placed to bring the ligth up to the top of the gun. (make sure the main diffuser bar comes back to the same point as the top down bar reaches the lights so that all the light will be used.

once all the glue has dried and set glue the wires into the rear shells and let them set.

now add the front claws onto the mounting points and posision them correctly.

Step 10:


PUCKA made it!(author)2016-11-04

and what this thing do? LED its all

MentosC made it!(author)2016-11-23

Your grammar simply does not make sense.

Please try again, and maybe I or backwards lamb can hep you.

Psiborg made it!(author)2017-03-31

he means that it isn't a real portal gun, but an LED emitter.

ZacharyH44 made it!(author)2017-06-09

Such a let down, isn't it? I would do anything for a portal gun

Psiborg made it!(author)2017-03-31

great job with this prop!

21jthayne made it!(author)2016-12-08

hehehe your not supposed to look down the front end of the divice

LenS12 made it!(author)2016-11-14

Hey! Thanks for the tutorial! Im a little confused as to how to connect all the wires to make them light up, I have an on/on switch, 2 large orange LEDs and 2 large blue LEDs and a 9V battery, how do I wire them so the on/on switch will toggle between the orange and blue LEDs while the battery is plugged in? Im not sure what your switch and LEDs are encased in but mine are just stand alone.

BenT131 made it!(author)2016-10-17

what's the estimate cost for this project in USD? i've got a budget of $30

backwards+lamb made it!(author)2016-11-04

I'm pretty sure it was more than $30 but I guess you could use techniques from this to make one for $30

I don't know the actual cost as it over 4years ago that I built it

Aarav2007 made it!(author)2016-09-30

hi can you explain what you did in detail and how you connected things and made a shell out of some insulation foam? because otherwise I will be stuck with my equipment and it will turn out that I used my money for nothing and that will not be accepted.

backwards+lamb made it!(author)2016-10-01

I'm not sure what you want? This whole post is how I made it in detail

I carved the insulation foam with a hacksaw blade , craft knives and sand paper. I glued three layers of foam together, like is stated in the steps about the shell. it is all connected together with glue I glued the shell onto the tubes. Theres not much more I can tell you other than the steps that are in the instructable.

t0731779j made it!(author)2016-08-15


t0731779j made it!(author)2016-08-15


t0731779j made it!(author)2016-08-15


t0731779j made it!(author)2016-08-15


t0731779j made it!(author)2016-08-15

i donot think itisreal

hami2228 made it!(author)2016-06-27

How do you make the claw things on the end of barrel?

ArachnoKing made it!(author)2016-05-22

nice project, ii intend to to do it some time

Willisuper25 made it!(author)2016-04-11

Hey! I really like your project, and i want to try it, can i ask you the density of the foam that you used in that project?

LightTrainSTEM made it!(author)2016-03-11

these really are amazing! I don't think I could create one in any short amount of time that I would have the patience for. And the same question as GLaD0SA, do you sell these?

backwards+lamb made it!(author)2016-03-11

I don't know, I have no idea how patient you are or how fast you build. You could Defoe make one relatively quick if you find a faster way to build the shells they were the most time consuming thing.

And no I don't sell them.

GLaD0SA made it!(author)2016-03-10

Where did you get the claw things on the front? I was also wondering if you sell these.

backwards+lamb made it!(author)2016-03-11

I made the claws no sorry I don't sell them

HimbeerT made it!(author)2016-01-04

Where do you get the PVC pipes :o?! I only get 75mm ore 63mm pipes, not 70 and 65 :/... Thank you for this instruction ;)!

backwards+lamb made it!(author)2016-01-05

hi, i got mine from a plumber friend but if you google you will find lots of online sellers, or you could try a plumbing hardware store. they dont have to be exactly the measurements i used something close will be fine.

The sizes i used are UK sizes the ones you quote are conversions from inches 75 is 3 inch and 63 is 2 1/2 inch.

bitzndprops made it!(author)2016-01-22

hi. what did you use for the front rings you put on barrel?

backwards+lamb made it!(author)2016-01-23

The three front rings on the barrel were made from layers of 5mm Perspex. The large rear ring is 4 or 5 (I can't quite remember) layers with a sanded edge to give it the chamfer and the other two smaller rings we 3 or 4 (depending on how many you make the large one) layers of 5mm Perspex and one of them had a sanded side to give it the chamfered edge to meet the barrel of the gun. Hope that helps.

bitzndprops made it!(author)2016-01-24

very helpful what tools were used to get them perfectly circular?

backwards+lamb made it!(author)2016-01-24

Well I used a laser cutter. You can use a template or hole cutter. Anything really.

HimbeerT made it!(author)2016-01-07

Ok thank you for your answer ;)!

JonR29 made it!(author)2015-11-16

Wow this is really awesome.i wish i had talent like yours.

coolT1 made it!(author)2015-09-11


backwards+lamb made it!(author)2015-09-12

That's an interesting response to my work. Please elaborate.

Logann4 made it!(author)2015-11-10

What he means is that this is so stinking awesome and he has no possibility of making one at such high quality so you ,with your impressive skills that he is jealous of, should die. LOLOL :D

Awesome job. I'm trying to build my own gun with everyday materials and plaster of paris to mold the shells with. Lots of spray paint, superglue, and plastic being used over here.

mccubee made it!(author)2015-10-26

I personally never played the game but nice job

Uradeyy made it!(author)2015-09-24

c'est génial ! tu as fait un magnifique travail, je suis impressionnée.

indywave made it!(author)2015-05-28

How much money and time dose it take to make this? P.s awesome instruckable!

--+_+NPC made it!(author)2015-06-26

How many time: Forever How much it is: 299 Dollars 99 cents

backwards+lamb made it!(author)2015-05-28

im sorry i couldn't tell you how much it cost me to make as i had a lot of the materials in my work-shed already and i scrounged the rest from plumber friends.

Also i cannot for the life of me remember how long it took to make it, it was over 4 years ago now.

GeekKiD2003 made it!(author)2014-06-08

Hey, backwards lamb! Cool prop! Maybe I'll try to make one! :)

backwards+lamb made it!(author)2014-06-13

do it, give it a go. If you do share a picture so we can see :)

IsraelP2 made it!(author)2015-04-25

Me again. on a differnt account. i coudnt ;-;

tardismaster made it!(author)2015-03-18

OMG This is awesome. I really want to do this for my halloween costume next year. :)

backwards+lamb made it!(author)2015-03-19

thanks. if you do make it post photos i would love to see it :)

tardismaster made it!(author)2015-04-19

Hi, Im working on my project now but the only material I can't find is the foam. Is there a specific store I can go to, like home depot or somthing?

backwards+lamb made it!(author)2015-04-20

I live in the UK so have no idea where you can get it from. But Google is your friend. :

I got mine from eBay.

AngelF2 made it!(author)2015-02-27


AngelF2 made it!(author)2015-02-27


tbh-1138 made it!(author)2014-02-08

Do not look directly into the operational end of the device.

Emily+Tristan made it!(author)2015-02-19

Exactly what I thought haha

About This Instructable




Bio: Im a model maker who makes film and game props in my spare time. If you like my work please visit my blog it has ... More »
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