Optimus Prime Ion Blaster

I found the instructable for the Optimus Prime costume and went to town on building my own. I wanted to take it a step further and add his main weapon. Here's how I made it. What you'll need: - 3" cardboard tube(s) - 4" cardboard tube - regular cardboard - Nerf Vortex Vigilon blaster - Hot glue gun/lots of glue sticks - 4" foam brush (handle only) - Spray paint (primer, semi-gloss black, blue)

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Step 1: Base/Back End

I used a Nerf Vortex Vigilon blaster for the base gun grip because it was cheap and looked cool. Found a picture online of the ion blaster and just guesstimated measurements. Came out pretty good I think. I got varying sizes of cardboard tubes from work and sliced them to fit over the gun and hot glued them on. The box on the back end is 5" wide by 7" tall by 4" thick.

Step 2: Middle/Barrel

For this, I cut o-rings out of cardboard to slide over and glue onto the smaller tubes to then slide into the larger tubes and glue into place. For the top and bottom add on pieces, I looked at the picture and guesstimated the size and shapes, then measured and cut several same shape pieces out, glued them together and then glued them on. Not seen here on the bottom box, added later, is the end of a foam paint brush. I was going to use a dowel rod, but it was only going to be like 3" so a foam brush handle was the cheaper option and perfect size. I used 3" cardboard tubes for most of the barrel. The back end near the box was a 4" tube. The overall length of the blaster is 37 3/4".

Step 3: Primer

Here's the whole thing...primed. Pun definitely intended.

Step 4: Paint

Semi-gloss black worked well, and I can't remember the name of the blue, but it was a light blue by Rustoleum. Any color close would work fine.

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    4 Discussions


    6 years ago

    Going from the tip of the barrel toward the back of the gun, it goes like this: Tip tube - 9", then 3/4" of smaller tube in between, a 9 1/4" tube, 2" of smaller tube, another 4" of main tube. Then the last tube by the box in the back is 7 1/2" long. That one is bigger than the rest. The long lengths for the rest of the barrel are the same diameter and the shorter gap pieces are all the same diameter. Hope this helps. Any other questions just let me know.

    1 reply

    Reply 1 year ago

    What width was the innermost barrel tube, and was the one you used for the O-rings: the 3" or 4" tube? BTW I LOVE this build!


    5 years ago on Introduction

    i am making a 10ft Optimus Prime costume but i mite nede a biger gun


    6 years ago

    Like this gun a lot. I'm trying to build one now, adding some electronics to it for sound and light. Hacked a walmart cheap o space gun and solder lights to longer wires to reach the front and 3 in dowel rod section. I know you said the length was 37.75 but what are the demensions of length for each tube? Please :)!!