First of all, this is not completely my idea. I think my design is unique, but in case it's not, I'm not trying to exactly copy anything I've seen online. My purpose is to show a different and possibly better design, and make a better/easier to understand/more descriptive instructable.
In this instructable I will show you how to turn a Buzz Bee "Double Shot" dart shotgun into an airsoft gun. I will teach you how to modify the shells to fire airsoft pellets; no modification to the gun will be made.
This shotgun can fire 1-3 bbs, the range and power just decrease with more bbs. Any more than 3 bbs won't go very far.
Its range should be about 50-70 feet, depending on the weight of the bbs you use and how well you build it. It shoots at an estimated 100-150 fps, also varying because of the weight of the bbs and quality of building.
Hope you enjoy and have fun!
DISCLAIMER: I am not liable for injury/damage caused by your use of this airsoft gun. Always wear eye protection when shooting, even just target practice. Have fun, but BE SAFE.
This is my first instructable, so any constructive criticism or helpful comments would be appreciated.
Step 1: Materials/Tools Needed
Approximate cost (excluding tools and tape): $25-$30
For this instructable you will need the following:
Buzz Bee Double Shot and Shells (The one in the image has a sawn-off barrel. You can do this with a hack saw or miter saw.)
Masking tape- preferably about 2" wide, but narrower is definitely OK
Nerf darts- don't need to be streamline darts, but I found them easiest to work with.
You will need as many Nerf darts as the amount of airsoft shells you want to make, plus a few to give room for error.
Standard Bic pen barrels- again, as many as the amount of shells you want to make
Airsoft pellets- .12g's or .20g's work fine. .12's usually have more speed but less power than .20's.
Tools/other implements (second picture):
Hammer or heavy pliers
Metal bottle cap or a hard, flat, surface
Sprue cutter, similar cutting tool, or xacto/hobby knife
Small screwdriver (should be able to fit into the hole in the back of the dart shotgun shells)
File (optional, but recommended)
Longnose pliers (optional)
Step 2: Components of Shell
The airsoft shell will consist of a two-piece barrel inside a nerf dart, which is then wrapped in masking tape and fit into the shell body. It will then be loaded into the gun and fired like the shells before modification.
The second picture shows the parts of the shell separated.
Step 3: Post Removal
To make it possible for the barrel to fit inside the shell, you must remove the post inside the shell (The rod with a cross-section like a plus sign +).
To do this, find a solid object with a small hole or gap in it (Like an old wooden picnic table) and place the shell, open side down, on top of it. The top of the post should be in the gap loosely, with the shell resting on its outer rim. Place the small screwdriver in the hole in the back of the shell. Hold the shell and put your finger against the screwdriver, as to keep it from falling out of the shell when you start hammering. Begin to tap firmly on the back of the screwdriver with the hammer. The post probably won't fall out on the first swing of the hammer, so keep going, increasing strength of taps if needed, until the post falls out.
The second picture shows what the shell looks like before and after the post removal (the shell on the left has the post removed).
The third picture shows the shell with removed post.
This is not needed, but strongly recommended.
Once the post is removed, you will see that a black "doughnut" of plastic is on the inside. This is held up by a spring. Use your screwdriver to press down on one side of the doughnut until it turns on its side. You can then use longnose pliers (depending on what kind you have), another screwdriver, or stiff wire shaped like a hook to fish out the spring. After removing the spring, it is okay to let the doughnut stay in the shell.
The fourth pic shows the spring (upwards of the doughnut) and screwdriver depressing the doughnut (sorry for bad image quality). Yes, that large object on the right side of the image is the handle of my screwdriver.
Step 4: Preparation of Dart and Barrel
Here you will prepare the barrel and nerf dart.
Take out the tip of the nerf dart. Begin by grabbing the tip and tilting it to the side. Then twist the tip from the dart, pulling a little bit as you do so. If you pull hard enough, the rubber tip should come out without ripping the rest of the dart (this is why you might need more darts than the amount of shells you're making).
The third image shows about where you should cut the dart and pen barrel. You don't need to cut the barrel into three pieces, but I find that cutting a little bit off the end makes it easier to load into the gun.
Dart- cut to about 2" long
Pen barrel- cut one half inch off the end, then cut the remaining piece into two pieces: 1 3/4" (barrel) and about 2" (bb chamber)
NOTE: you can vary the lengths of the two pieces of barrel to increase range and/or accuracy. The examples I give are just there to help you. make the bb chamber as long or short as you want, just make sure it can hold the amount of bbs you want to shoot.
Shell- no cutting required
Step 5: Further Preparation of the Barrel
In this step you will further modify the barrel.
First, you will put a "rim" on the inside of the bb chamber. This is to prevent the bb from falling out of the shell, and to let air pressure build up behind the bb before it is fired through the barrel.
Use the lighter and hold the bb chamber up to the flame while rotating the chamber. Only do this for 1-2 seconds, or your bb will not be able to pass through. Immediately after softening the end of the bb chamber, roll it against the bottle cap (flat surface) very gently. This creates the rim.
Test your rim by putting a bb on it and forcing the bb through. It should go through very easily, but not easy enough that the bb could roll through it. If you find that you have to push a moderate amount on the bb (a noticeable acceleration of the bb after it goes through the rim) then put one blade (or both) of your sprue cutter/xacto knife in the bb chamber and scrape gently at the rim. When looking straight through the rim, it should be relatively even on all sides.
Merging the barrel with the chamber:
Put the rimmed end of the chamber on a piece of masking tape about 1 1/2" inches long. Place the end of the barrel on the masking tape, touching the end of the chamber. Roll the masking tape around the chamber and barrel, joining them.
Your bb chamber and barrel should align properly (image 7).
Step 6: Assembling Shell
Put the barrel/chamber into the dart. You should do this slowly, or risk tearing the dart. Slow rotation of the barrel/chamber will probably be needed to get it in the dart.
Wrap the dart in about 2-3 layers of masking tape. Doing this prevents the whole barrel assembly from flying out of the shell when firing.
Put the assembly into the shell. It should be a tight fit, but not so tight that it is impossible to remove. Once the barrel assembly is in the shell, make sure the barrel points straight out of the shell, not at an angle or the bb might bounce around and will be inaccurate.
Image 4 shows how it should look when it is done correctly (barrel straight). Image 5 shows what is incorrect (barrel not straight).
When pulling the barrel assembly out of the shell, always pull it out by the dart, not the barrel.
Step 7: Loading and Firing!
To load the shells, take the barrel assembly out of the shell. Always take it out by the dart, not the barrel.
Hold it dart-side up and place 1-3 bbs in the bb chamber (which is mostly covered by the dart). Only put one .20 gram bb in the bb chamber, but feel free to put three .12 bbs in the chamber. Any more than one .20 will not shoot far.
While keeping the assembly dart-side up, place the shell (opening down) over the dart. If you flip the barrel assembly, the bbs will fall out. This is why you keep the barrel assembly and shell inverted while loading.
Open your shotgun all the way (like normal) and put the shells in the chambers. Make sure that the barrel of the shell does not snag on the spring inside the shotgun barrel. Close the shotgun fully.
Pull the trigger.
Be safe and have fun!!!
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