Introduction: MIB Halloween Costume

About: I'm a former bicycle industry designer turned professional jeweler. I like working with my hands and am happiest when I'm in the shop building my creations. If you need help with your project just let me know!

Be a MIB agent for Halloween! It's a simple costume to do but to really make some impact you'll want to pull out the "big guns."

Step 1: Materials

First you'll need the obvious black jacket (preferably three button- I used a two button black blazer and added the third button), black pants, black shoes, black tie and white shirt. Don't forget the dark glasses!

Now for the fun stuff- for the blasters you'll need some MDF wood, sheet plastic or Sintra (PVC sheet sold by plastic suppliers and sign shops- cost about $35 for a 4x8 ft. sheet 1/8" thick), some wood screws, Bondo, epoxy, PVC cement and a few lengths of PVC pipe.

Step 2: Pulsar Blaster

My blaster of choice! The blaster body is made from two lengths of PVC pipe that are glued and screwed together. Then glue a piece of Sintra (use PVC cement) to create the flat section between the two PVC pipes (this is the Bondo covered section in the photo.)The bottom section is notched out and some Sintra sheet is then glued in and then a piece of MDF is epoxied and screwed to the flat Sintra sheet. This notched out section is what holds the slide on the bottom of the blaster.
The slide handle is made from a cut section of PVC pipe with ribs glued on. It has a piece of MDF glued inside it to hold the bearings for the slide. The slide itself is a surplus computer rack part I found at an electronics surplus store- a drawer slide might work as well (or just screw on the handle to the bottom of the blaster if you don't want it to move.)

Step 3: Pulsar Blaster Step 2

Now make back section of the blaster. The bottom piece of MDF (the part that holds the slide) needs to extend all the way back to the grip section. The grip is made from a piece of MDF and has some Sintra sheet glued onto the sides. The area above the grip is a piece of wood (a 2x4 scrap) that has Sintra sheet glued onto it. The funny looking wood parts above the grip are cut from more 2x4 wood scraps and have dowells glued into them. The rounded section directly in front of this is made from two differnet diameters of PVC pipe and has some Sintra sheet glued on. This is then blended into the forward section of the blaster with some Bondo.
The box section on the bottom of the blaster is made up from some Sintra sheet and is screwed onto the MDF section that holds the slide. The "shells" are made from wood dowels and have rubber furniture bumpers screwed into them.
The top section of the blaster is made by gluing a vertical section of PVC pipe and capping it and making the long flat part that curves and extends to the front of the blaster. The back part of this (the part that is green in the photos) is made by gluing some PVC rings onto a clear acrylic tube. I then inserted an old mountain bike fork bumper (the geen part) and made the cap for the rear out of scrap wood.

Step 4: Pulsar Blaster Step 3

Finishing up the front- the front of the blaster is made by reversing a PVC pipe adapter and gluing it to the front of the blaster, making sure to file off the extra material so it blends smoothly with the PVC pipe. The triangular shaped section above this is cut from some MDF and epoxied to the upper section.

Step 5: Tri Barrel Blaster

This blaster is built much in the same way as the Pulsar Blaster. First make the barrels from some PVC pipe and glue some PVC couplings onto both ends. The main body of the blaster is made from hollowed out sections of MDF that are glued together and then sanded smooth on the outside ( a belt sander works wonders here.) The front face of the blaster body then has three holes bored into it to accept the PVC barrels, which are epoxied into place. The blue dome was made by squirting some blue dye into some clear casting resin- a cheap dome light was used for a mold.

Step 6: Tri Barrel Blaster- Step 2

To make the slide ( I used the same bearing slide as the Pulsar Blaster) first glue a section of Sintra onto the bottom barrels and screw it to the PVC pipe. Then use screws to attach the slide to the Sintra sheet. The handle for the slide is made from MDF and the grooves were cut in with a round nose router bit.
The shells are made from wood dowels with furniture bumpers screwed on. Some more Sintra sheet is then wrapped around the dowels and screwed on. To make it easier to bend the Sintra soak it in boiling water for a few minutes and once it's bent to shape dunk it in cold water to freeze it.

Step 7: Tri Barrel Blaster- Step 3

Now bore a bole in the back of the main blaster body for the shoulder stock. This was made from a couple sections of aluminum tubing with a plastic rod glued in. The shoulder part was made from MDF. Another hole is then bored into the bottom of the blaster and the grip is epoxied into place. The details on the side of the blaster body are hose barbs and washers glued on so clear tubing can be added later.

Step 8: Tri Barrel Blaster- Finishing Up

Now add some details to the other side of the blaster body. This is made from a dowel with grooves cut into it, a knob epoxied on and a small piece of plastic sheet with holes drilled into it. Addtional dowels are cut at an angle and glued onto the back of the blaster body and have allen screws set into them.
The front of the barrels is finished by cutting a piece of Sintra sheet and gluing it onto the front of the barrels.

Now give both blasters a coat of primer and then a coat of silver paint!