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The aim of this project was to repair my broke, old, and cheapy plastic airsoft gun.
The project cost me around $12 and took about 3 weeks to complete (working little bits each week. A lot of stuff I used I already had around the house. I hope you enjoy this instructable and I hope you use it as a jumping off point for your next project. This instructable will be in the Craftsman Tools, Joby Transform It, and Epilog Challenge contests, so please vote for me, it would be greatly appreciated.

-Below is a picture of a basis for my gun design.



Step 1: Materials Needed...

Here is a Basic list of what I used and what you might want,

Parts
-Old broken airsoft gun (mine was smashed to pieces and wiring was needed)
-2 part epoxy or strong glue
-Wood glue
-Scrap wood
-Old rag
-Wood Stain
-Solder 60/40
-Electrical Tape
-Spray Paint (newspapers for spraying on)
-A Good attitude ( I didn't have this all the time haha)




Tools
-Hot glue gun and glue sticks
-Knife/Razor Blade
-CRAFTSMAN Jig Saw
LINK: http://img1.classistatic.com/cps/po/100923/451r4/30747f5_26.jpeg
-CRAFTSMAN Belt Sander /
Sandpaper 
LINK : http://www1.epinions.com/reviews/Craftsman_1_hp_Belt_Sander_11715
-Cordless Drill w/bits
-CRAFTSMAN Corded Drill w/bits
-Soldering Gun
-C Clamps or QuikClamps
-Shop Vac for cleanup
-Wire Stripper

Step 2: Repairing the Shooting Mechanisms.

You'll need...
-Electrical Tape
-Soldering Gun
-Solder
-Extra Wire
-Wire Stripper

My shooting Mechanism needed some soldering so that the tiny DC motor would crank the gears to fire. I soldered up the leads that I needed to, then covered them in electrical tape. This Instructable is a jumping off point, not a step-by-step really, so do as YOU need.
The battery also needed some soldering.

Connect the battery to the firing mechanism and test it, we wouldn't want to put it in the case to find out that it doesn't fire.

Step 3: Housing the Shooting Mechanism.

You'll need...

-Old plastic Housing
-Hacksaw
-Screws (small, good if you kept the old ones from the gun)
-Screwdriver
-Shooting mechanism
-Trigger/Trigger spring

I cut the original plastic casing to how I wanted the gun to look using a hacksaw. I then placed the mechanism and trigger inside, getting the trigger in with the spring was hard for me. I tested the  safety mechanism and it worked so I moved on to screwing the case in place. The barrel also fit inside the casing, the mechanism works by pin reciprocation, hitting the bb down the barrel each time.

I tested the gun using 2 bb's and it worked so I was free to move on.

Step 4: Painting the Housing.

You'll Need...

-Newspaper
-Open Space well ventilated
-Spraypaint 
-Gun Casing
-Knife 
-Painters tape

I used the knife to cut the painters tape into custom pieces that would cover openings, ensuring paint would not get inside the mechanism. I applied the tape, took the gun outside and applied two coats of an "army man green."

Let the gun dry and remove the painters tape. On to the next step!

Step 5: Creating the Stock and Barrel Grip.

You'll Need...

-Scrap Wood
-Jigsaw
-2 Part Epoxy
-Wood Glue
-1 Fastner' wood screw 1/2 inch
-Jigsaw
-Beltsander
-Corded and Cordless Drill
-Drill bit about the size of the Fastner' (Varies)
-Drill bit about the size of the barrel  (Varies)
-The gun so far
-Clamps

This was the most time consuming step in the gun transformation.

I started by taking a length of wood about 2 inches shorter than the barrel, that fit nicely into my hand - this became by barrel grip. I found the center of the wood, and drilled a hole using a long drill bit with a width similar to the barrel, so the barrel would fit snuggly inside. Despite having a table sander, I took my belt sander and smoothed the barrel grip so that it made a semi-circle-ish curve that would be a nice smooth grip.

I then took a 1/2 inch sheet of wood that would make a nice butt for my arm length, this is customizable. I drew up a stock based on the picture in the first step ( I freehanded the design so I am sorry there is no print-out). Once drawn, I cut out the stock using a jigsaw, and sanded the edges smooth using the belt sander. I made a small block so that the butt could be glued to the casing. I did this by gluing the small block to the stock then drilling a small hole through both the stock and the block - I then used a fastner' to secure it  (This is hard to explain, so look at the pictures below).

On to the next step...

Step 6: Attaching Custom Parts.

You'll need...

-Hot glue gun / glue sticks
-JB Weld/ 2 part epoxy. Along with materials to mix the epoxy in. ( i.e. pie tin/ Popsicle stick)
-CLAMPS!
-Shop Towels to clean up with.


Mixing the epoxy is messy, so do it in a well ventilated outdoor environment.

Once you have mixed your epoxy, or you have your glue at hand, attach the butt of the gun to the casing using epoxy applied to both sides - have clamps and things ready to prop the parts up ready. Let this dry. Repeat with the barrel grip.

My gun came with a scope that acted as a hopper for pellets. I used epoxy and clamps to glue this back on, making sure the 2 holes where pellets pass through lines up perfectly - can't have mistakes with strong glue.

For the metal barrel part, sight, and muzzle, I used hot glue because it drys faster - these parts are very HARD to clamp and keep position. Metal barrel, sight, and muzzle were all harvested from the old gun and are not custom.

Let everything Dry, and on to the next step!

Step 7: Staining Wooden Parts.

You'll need...

-Wood Stain
-A Rag or Paintbrush
-A well ventilated area.

Staining is very easy. If you use a paintbrush, you will need to use solvents to clean it, so I went with the easy approach - an old rag. An old rag works perfectly and you can throw it away when your done. Apply the stain using the rag to wooden parts, let it dry, and re coat as needed.

Were almost done! To the next step!

Step 8: Load, and Fire!

Insert the battery pack, I salvaged mine and it inserts into the gun as the magazine. NOTE: KEEP THE ORANGE TIP ON THE GUN DO NOT PAINT IT BLACK THIS ALLOWS CIVILIANS/LAW ENFORCEMENT TO KNOW THE WEAPON IS NOT REAL.

Have fun with your new gun, and feel accomplished - I know i did because I was ready to trash the broken gun.

For a project under $12, it was fairly easy and gun looks good now. The old gun was broken in pieces and had been through a helluva lot. It cost around $30 and I got it around 4 years ago.

I was thrilled when I was done, and had fun shooting. I hope you enjoyed this and use it as a guide for you next airsoft project.

Please vote for me in the Craftsman Tools, Joby Transform It, and Epilog Challenge contests, CHEERS!

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