Introduction: Call of Duty : Ray Gun

About: Currently and engineering student with a design flare.

  This project commenced as soon as I saw the game of life contest open. I did not see many people build the ray gun so I decided to go for it! I used the to scale blueprints to assist me and make reference to throughout the project. I found them really helpful and I hope you will too.
Link :
  This project consists of mainly scarp wood but also scrap metal and PVC tubing, these were all found in the house shed. Sometimes to meet the required thickness. So therefore it was mainly free apart from the paint I had to buy. My Dad helped me cut the PVC tubing in the chop saw as it was highly dangerous and also thought me a new skill, how to chisel. I enjoyed this project a lot because as the final week approached I was under pressure to get things done so I had to add time management to the project so it would be finished on time. Basically I gave myself a task for everyday. Eventually I did get it complete and I was very satisfied with the result. This project is most rewarding to whoever is going to try it especially fitting all the parts together.
  Best of Luck!

Step 1: Tools and Materials.

You don't need any of the stuff here apart from a few things because this project is so versatile. You can make it out of cardboard, foam, metal or wood. 

Materials used;

Brass bars,
Aluminium tubing,
Coat hanger,
Plastic (From a bottle),
A washers,
PVC pipe,
A handball.

Tools used;

A screw driver, (Not necessary)
A jigsaw, (You could use a saw)
A drill,
Rotary tool, (Not necessary)
Hammer, (Not necessary)
Clamps, (Not necessary)
Chisels, (Not necessary)
Sand paper,
Various glues.

You will also need paint.

Step 2: Handle

I started with the handle. Using the blueprints I marked the template onto the wood I was using. It has to be 30cm thick. To recycle my scrap wood in my shed I glued two pieces of wood together to save money but to also achieve the correct thickness.

Once the template is marked on the wood  I clamped it down securely and cut with a jigsaw.

When the final shape was cut out I finished it off with sandpaper.

Step 3: Barrel

Next I moved onto the small barrel. For this I used an aluminium tube, a nail, two rings, plastic, a necklace bead and an old handball cut in half or you could use anything semicircular. 

I cut the handball in half with a hacksaw and drilled a hole in it so the aluminium tube could fit through it.

Then I got my cork and drilled a hole in that too. It fit nicely over the aluminum tube. Slide the handball down the tube so the correct length is achieved and trim off any excess. Also slide two gold rings onto the tube. I used plumbing fittings.

Stick a nail into the corks and on the tip of the nail add a small necklace bead.

I cut out the shark like design out of a plastic bottle and super glued it onto the barrel.

When everything is correct I painted it the desired colour.

Step 4: Back Part

For the main circular bit of the gun it has a width of 60cm.
I copied the template twice onto the wood as the wood was 30cm and jigsawed them both out. I then stuck them together and finished the piece with sandpaper.

Using a rotary tool and sandpaper I made a slight curve around the edge of the piece at the side to meet the gun requirements.

I then again copied the detailed squares for the gauge onto the side of the piece and chiseled them out. Not too deep!

For the rectangular silver bars at the back of this gun I marked them onto thin wood and cut each one out using a jigsaw. I then painted them silver.

For the the bars at the back that stick out I used brass bars cut to size using a hacksaw and bent them in a bench vice with the assist of a hammer.I drilled holes in the circular piece for the bars to fitted in. they should be at equal depth. Make any bending adjustments to the bar if necessary.

Step 5: Middle Parts

For parts 1 and 2 (see pictures) I cut out two squares. I cut the outline of the blue prints (side view) out to mark the curves on the sides of the two squares. I used a rotary tool and sandpaper to achieve these curves. I had to use a lamp as it was dark in the night.

Remember to always take a break once in awhile and enjoy some apple juice :)

Once the pieces were finished I glued them together and cramped them. Be sure to always keep checking your pieces with your blueprints to ensure you're on track. Also ensure they fit onto the previous part nice and snug.

Step 6: Barrel

This is the larger barrel. It was made from plastic from a bottle, PVC pipe and coat hangers.

I cut the PVC pipe to size about 2cm longer so I could stick it into the previous parts. I then cut the PVC pipe in half.

Next I cut a square piece of plastic from a bottle, sanded it and the hot glued it in place onto the half PVC pipe.

I then bent 3 coat hangers around a PVC pipe so it could slide over the barrel. I cut them to size and the hot glued them in place.

Step 7: Assembly

1. I began with securing the handle to the middle part. I used wood glue and a dowel.

2. Next I decided to glue the back part to the handle and middle part (above).

3. I glued the top part then after. (Now paint before advancing to the next step)

4. I drilled a hole about 2cm deep using hole bits into the middle parts so I could insert the larger barrel into them. I placed the barrel into this hole and secured with glue.
Before you glue anything make sure the PVC pipe is painted.

5. I then added the smaller barrel to the larger barrel using hot glue.

Be sure to do any painting required before doing assembly, apart from step 1-3.

Step 8: Finishing

For the finishing I added the rectangular bars to the back along with the bent bars with washers. I also added a the two switches. I also added strips of aluminium to again make it look better. On the smaller barrel I added a aimer using a straight nail and washer. I also touched up the paint where it needed. Also I added wood filler to small gaps and painted over it.

Step 9: Conclusion

I am very satisfied with the result. I really like it and I hope you do too! It took me a very long stressful time and interfered with school work. I didn't get to relax all this week but it payed off. At least I didn't sit on the couch doing nothing. I made my previous two weeks productive and rewarding.

Trial and Error;
  • I made a mistake with the back part. As you can see it is upside down. So therefore the gauge would be upside down.
  • Do not use coat hangers there very hard to bend and work with.
I could not source any official stickers for the ray gun.

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Epilog Challenge V

Participated in the
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