Nerf Vulcan Modification Project




About: Industrial / Manufacturing / Systems / Quality engineer with a passion for gadget making and emerging technologies

In this Instructable, I will be documenting the modifications I make to my new NERF Vulcan EBF - 25 fully automatic Nerf gun.

Many of these modifications are NOT REVERSIBLE , and, if done wrong, will result in irreparable damage to the gun.

Also, i know it's kind of obvious, but performing ANY of these modifications will immediately void the warranty, so don't complain that the store refused to take beck your broken gun! - Note, Some people have commented that Wallmart took back their broken guns after failed mods. THIS IS NOT NORMAL! Toy companies do not follow the maker's creed of "If you can't open it, you don't own it!"

I will also point out key parts that I think should be made of metal, along with CAD drawings of said parts.

All the images in this instructable are available in high quality (so you can actually see what I'm talking about). Just click the boxed "i" in the top left of the image, and click "Original File"!

And, as always, wear safety glasses when playing with modified NERF guns, the darts won't have much of a problem giving you a black eye!

DO NOT MOD A NERF GUN WITH BATTERIES IN IT! 9 volts isn't a lot, until you add current!

The steps are numbered in the following manner:

M # P #, Name
meaning: Mod # Part #, Name (if first part)

Like what you see? Flattr me!

Teacher Notes

Teachers! Did you use this instructable in your classroom?
Add a Teacher Note to share how you incorporated it into your lesson.

Step 1: Pre Mod Stats

Here are the stats on the gun, Pre-Mod:

Flight Distance:
Initial 50.27777778'
Bounce 5.861111111'
Total 56.13888889'

Looking at these numbers, the gun did really well pre-mod, better than any other Nerf gun I've used.

Step 2: M1 P1, Belt Air Restrictor Removal

The belt on the Nerf Vulcan has some annoying air restrictors in it that need to be removed, but, if you cut too much plastic, the gun won't work.

This mod doesn't do much on it's own, but combined with the removal of other air restrictors, it's incredible.

Step 3: M1 P2

I used a drill bit and a knife to hollow out the tube, but anything that gets the job done should work.

This is a long and tedious mod, since it has to be repeated many times.

However, it's probably the easiest mod to do, since you don't have to disassemble the gun.


If you installed the handle and bolt, read this step, otherwise, skip to the next one.

Step 5: Feed Cover Removal

In order to access the innards of the gun, the feed cover must be removed. to do so, take out the two hinge screws.


The longest part of disassembling the gun is taking out the screws, and there are a ton of them!

Luckily, not all of them need to be removed!

Step 7: M2 P1, Master Air Restrictor Removal

In this mod, we complete the belt mod by removing another air restrictor.

Use extreme caution when lifting the piston out of the action, there are many thin plastic parts that could snap of bent wrong.

When I first performed this mod, the firing distance actually dropped, but i quickly figured out why: The master air restrictor acted as a chamber seal during the firing sequence. Without it, it is necessary (on some guns) to spread a bit of Vaseline or other gel on the tip of the plunger chamber (marked in picture). This will greatly improve the function of the gun by keeping the seal moist, and airtight.

Step 8: That's It, for Now.

For now, I'm done modding my Vulcan, but there are plenty more mods I'm planning.

I will update this Instructable with future mods that I do!

Future mod list:

  • Round Counter
  • Extended belt -- maybe not, this would put too much stress on the belt feeder (if the belt was hanging)
  • Rechargeable battery - possibly an old laptop batt?
  • Better ammo box
  • Better belt feed - see next item
  • Metal components (and CAD Drawings)
  • Stefans (requires belt post removal...)
  • Rewiring
Like what you see? Flattr me!



    • Make It Fly Challenge

      Make It Fly Challenge
    • Stone Concrete and Cement Contest

      Stone Concrete and Cement Contest
    • Indoor Lighting Contest

      Indoor Lighting Contest

    135 Discussions

    yuzuru otanashi

    5 months ago on Step 4

    If your interested, I made custom top carry handle pins that are 3D printable. I'd be happy to send the g-code file.


    2 years ago

    Cool, but one question: how exactly does removing the air restrictors improve the gun's overall stats?

    1 reply

    Reply 2 years ago

    The air restrictors function by limiting how much air can go from the piston to the dart. Once the dart moves the first 1/2 inch or so, the restrictor closes blocking the rest of the air in the piston. By doing that it limits the speed of the dart. When it is removed, all of the air in the piston can be used to propel the dart down the barrel. For some blasters, it does not make a large difference, but for others, it can make a huge difference and seriously improve the performance.


    6 years ago

    awesome thx


    Im going to buy two slightly used nerf vulcans from a friend, can you reverse the polarity of on of the belt motors and do some cosmetic changes to make one of the guns belt feed from the opposite direction and still work.

    4 replies

    Reply 7 years ago on Introduction

    sadly no, the feed mechanism is a One Way ratchet that works by pulling an angled lever past teeth on the belt holder, regardless of which way the motor turns, that part will still pull the belt in the same direction.


    Sadly that won't work... The firing mechanism works by reciprocating motion, and the belt advance will only work in the correct direction. I ruined my first Vulcan when the belt got pulled backwards, and broke the ratchet mechanism...


    7 years ago on Step 2

    I have a used vulcan, and it isnt shooting as far as it is supposed to. Will changing the batteries help? Thanks

    1 reply

    Reply 7 years ago on Introduction

    Wow it's been a while since i've logged on, sorry, but yes, replacing batteries will help a lot on firing speed.

    Distance won't change, since regardless of speed it's still pulling the bolt back the same ammount, but at some point the motor won't be able to get the bolt all the way back. Try putting in new batteries and it should work better!


    7 years ago on Step 3

    A much easier and cleaner way of doing this is to use a small pair of wire cutters and simply snip the pieces of plastic holding the pegs in place. Two quick snips on each peg and you are done. It took me less than 5 minutes to remove all of the ones from my belt.


    Cool Mod! I did not take the AR out of mine I actually Modded it to run on a
    9.6 Volt RC Battery And it worked really well! So I got a new Vulcan and I thinl i am going to Take out all the AR's then mod it to run on a RC Battery? Sounds Legit right?


    7 years ago on Step 5

    So, I have a Vulcan, and it's NOT that easy to take off the feed cover. I took out the two hinges screws and it wouldn't come off. Is there something special needed? Because something is holding both sides in.