Here are snapshots of the first set of fiberglass parts pulled from my PPSh-41mold set, with the milling pattern masters for the hardwood stocks. The fiberglass parts are made with an aluminum-filled gelcoat, so they can actually be polished like metal. I will spray them flat black and buff to expose the silver underneath to make them look "battleworn."
Last Edit: Dec 9, 2007 12:50:59 GMT -5 by Guinness
The molds are made from a pourable silicone rubber I buy from Sterling Supply in Minneapolis, but lots of places manufacture and sell moldmaking silicone. I made patterns for the receiver mold, but the drum mag mold was pulled from an actual drum mag. The metal gelcoat is made with powdered aluminium from www.sculpt.com, mixed into a general-purpose layup polyester resin catalysed with clear MEK( Methyl Ethyl Ketone peroxide) and backed with a wet-laid layer or two of ounce-an-a-half fiberglass matte. I usually get my fiberglass supplies from North American Composites, but they only sell by the drum and the 98-lb roll; for small jobs, you can buy resin and matte at any decent-sized auto body supply store or sometimes from a boat repair shop. It's toxic and messy and it stinks, so you need a respirator and disposable gloves and a household-authority-figure-approved space to work, at the very least. The dust produced from the cleanup grinding is pernicious stuff - since it contains fiberglass bits, it sticks to skin and clothing and itches terribly.
Thanks for the kind words. I will be doing four with hard maple stocks in the this first test run, and will post when I'm ready to start taking pre-orders for the next, larger production run. Introductory price per gun for WW2AA folks is estimated to be $495 US plus shipping - this is close to at-cost for me, but hey, it's for the Motherland. The mag well is a vulnerable point on this gun so as of right now, I'm only planning to offer it with a fixed 200-rd hi-cap drum mag - since the original mags took 72 rounds, that should be about right according to the "3-to-1" airsoft mag-capacity rule of thumb. More soon....
I'm very impressed! Having worked in the fibreglass trade myself, I'm curious as to whether you've made the barrel shroud as a laminated 2 piece or as a casting? If you've got all that detail and shape out of a single mould, I'm extremely impressed! (Not to mention curious as to how you did it!).
Last Edit: Dec 9, 2007 20:37:18 GMT -5 by petee99d
Tommygunner, I'm aiming for $495 for an assembled gun with AGM M14 internals, fiberglass receiver, fixed hi-cap fiberglass drum mag, and oil-stained hardwood stock. Basically, I'm completely eating all my up-front tooling costs to offer these at this price. I used leftover silicone for the mold and so I figure, I was going to do this gun for myself anyway....
peetee99d, I didn't have the guts to attempt the receiver as a one-piece layup - I've done one-piece cylindrical layups on big things like full-size faux tree trunks where you can see and reach up inside to correct the lay of the glass at the seamline, but this was too small and fiddly to contemplate. I laid the receiver up in halves, cleaned the edges on a benchgrinder, cut the side slots with a forsner drillbit and an 1/8" Rototool Sabrecut bit chucked into a dremel, laminated the two halves together with wetted-out strips of matte, cut the top and bottom slots and front sight detailing, filled the seams and sight centers with aluminum powder "gelcoat," and dressed the seams flat.
The receiver is by far the most involved piece on this replica so far (but then, I haven't rigged the BB feed yet.) The layup and filling is no big deal, but I wish I could come up with a quicker way to do the front sight and cooling slots. An injection mold with slots in place would be an expensive bit of tooling work. If there is more interest in an airsoft PPSh-41 replica at this price than can be met with fiberglass, I'm toying with the idea of vacuum-forming the receivers in halves out of 3/16" black ABS, so that the slots could be cut out with passes of a bandsaw.
Wonderful that you're offering them so affordably to this audience. Once done and sorted out you should figure out what would make sense commercially in volume as I truly think you could sell a bunch of them. Your workmanship appears truly outstanding and very very clever.
As Schmitty said this is an exciting time to be involved in WW2 airsoft. Great effort!
Stalin should have known communism wouldn't work. There were red flags everywhere!"
It looks outstanding! You've given me inspiration for how to go about this myself. I have a deactivated PPSH and have been looking for a way to use it without breaking our stupid UK gun laws. I only plan a one off myself, so can use the real sights, etc.
I hope you sell shed loads of them! We all need more Russians to shoot at.
Dracul: It looks like it lost a lot of steam and I now feel bad for randomly dropping off.
Jun 15, 2018 14:58:17 GMT -5
stuka: I mean it's not your fault. It is interesting though that things are falling off as we are finally getting our ww2 guns with the type 38/96 and the enfield as well as it recieving a new loading system, it's kind of unfortunate
Jun 16, 2018 3:30:04 GMT -5
Dracul: I don't know, maybe its because all the guns are becoming available, there is a decreasing need for the forums.
Jun 16, 2018 16:29:26 GMT -5
Dracul: Most of the talk was about making guns, as all the uniform info was already out there, but now the weapons are out there and are usually decent quality.
Jun 16, 2018 16:33:32 GMT -5
stuka: well the forum is and should still be useful for updates on guns, creating groups/events and building kits
Jun 18, 2018 1:33:29 GMT -5
Cpl. Hicks: I haven't been here in years, but I'm glad to see this forum is still kicking! So much great info on here.
Jun 22, 2018 14:00:12 GMT -5
savoy6: anyone know if anyone still carries the enfield?
Jul 15, 2018 18:47:08 GMT -5
Dracul: I think Redwolf has a Enfield. If not or not longer, then not until G&G releases theirs. The old gas Iron Airsoft brand SMLE isn't carried by anyone anymore and was such piece of crap. Not worth trying to track one down.
Jul 19, 2018 5:55:35 GMT -5