This is an Instructible for creating a minigun from Team Fortress 2 for cosplay or whatever.  This covers creating a basic minigun with spinning or fixed barrel.

This was made at LVL1, Louisville's Hackerspace.  (see more at http://www.lvl1.org)  Be sure to check your area for a hackerspace, they're a great place to meet new people, learn new things and get access to awesome tools.

Having a laser cutter or CNC machine will really help with this build, but they're not required.  The pics in this tutorial were all taken after the gun was built, so everything is its final colors.

When building my weapons I try to make my weapons scaled perfectly and worry about the details later.  There are a lot of miniguns out there, but most of them are scaled horribly.  To me, the details don't really matter as long as the weapon is scaled properly.

Laser cutter or CNC machine
band saw
miter saw
belt sander
hot glue gun
tin snips
rivet gun
box cutter
really long Phillips head screwdriver

Rough List of Materials:
1/2" foam board
1/2" plywood
3/4" PVC pipe 10'
1/2" PVC pipe about 3' long
1/2" conduit about 1' long
4" PVC coupler
4" to 2" PVC adapter
3" PVC pipe 1' long
2" PVC pipe about 2' long
sheet metal
12" long 3/8" diameter threaded rod
6x coarse 3/8" nuts
4x 3/8" lock washers
2x 3/8" fender washers
4x 3/8" washers
3/8" inner diameter bearings
12v battery
belt (and pulleys if you don't want to make your own)
Mod Podge
craft foam
black and white paint
other bits of scrap wood
MadameNeko1 month ago

Can I buy one from you? My friend wants to cosplay as the Heavy, and I would like to help her out. :)

There is a free Steam gift card giveaway at http://getsteamgifts.com/ Works for all countries!

Ethansaurus4 months ago

Free Steam games: http://getsteamgifts.com/ Works for all countries!

coryalex1 year ago

Thank you for inspiring me! I'm building my own Sasha, now.

I'm 3D modeling most of the parts, and I've got just about all the barrel components done. She's coming along beautifully. I'm going to do a test fit to verify motor operation (and lights... yes, lights). Then I'm on to other parts of the build.

I plan to have it done no later than May (for Phoenix Comicon 2014).

Thanks again for the inspirational Instructable. :)

popeye12311 year ago
Okay on the barrel what is the front housing made out of? It looks like big piece of PVC pipe but you do not state what it is.
So i herd u liek maxez.
JackDF2 years ago
what does modge podge do to the foam, is it like a detail filler?
RedWagon (author)  JackDF2 years ago
The primary reason for it here is to prevent the spray paint from melting the foam. Bondo is a much better detail filler since you can build it up and sand it smooth. Modge Podge is basically white glue mixed with water so it can fill details about as well as latex paint.
crayzeedude2 years ago
Is it possible to make this without some the machines (i.e. CNC, saws, etc.)? I, sadly, do not have access to much of them.
what kind of foam did you use?
xeon_hl22 years ago
This is just pure win :D, good job.
poofrabbit2 years ago
Congratulations on being a finalist in the Halloween contest!!! Can’t wait to see if you win! Good luck!
carlsands3 years ago
vulcan243 years ago
I can has Maxes?
pretty nice looking.
I want one
propfreaks3 years ago
Awesome tut! Just fyi, I posted to it on my site, www.propfreaks.com.

Thanks for the great effort!

On a side note, I love the at, where'd you get it?? xD
I made it :3
That is awesome, do you think you are going to post how to make it someday?? :3
Of course! I started to take pictures while making it, but then got lazy, and stoped. So I have to remake it and actually take pictures this time. ^_^;
That would be awesome, I did the same thing when I made a pair of swimming trunks last year, I still made the trunks, but next time I make a new pair, I need to use different material. These retain too much water.xD
sheldor3 years ago
WOW! That is definitely the coolest roll of toilet paper ever seen! Lovin' it! ♥
Sasha is awesome, kudos to you my friend. This is a job well done. :)
erzee3 years ago
Great job! It's nice that this version doesn't cost $400,000 to fire for 12 seconds.

I mashed 'Vote' several times. Hope that helps!
mikeasaurus3 years ago
Well done, such awesome pictures!

Wait...no sandvich?
sonicase3 years ago
it spins!