Knowing I can only cut once at the top, I cut several different size holes in a 2x4 & put the sphere in each hole. I finally decided after constant back & forth between the reference images & the sphere, to use a 1 1/4" drill bit.

To replace a possible bulb burn out I started with a pop bottle top, ground down & a 7/8" wood dowel.


I used breadboard pin cables (I think that's what their called), to insert the LED's.


Inserting the LED cables into 6 drill holes, 2 for each LED, in the wood dowel & screwed on the cap.


I put the other end of the bottle top in the gun.


Once I wired up the trigger & AAA battery pack to the lights, I figured, the battery pack would determine how you hold the gun. If your right handed, it would be on the left & vice versa.  Simple hot glue to nail down the battery pack.


All I need to do now is wait for my acrylic rod to come in the mail, measure out my clear acrylic discs & send out for some highlighter pink acrylic.


I found a web site that will make & cut the acrylic. I just need to give them the measurements to my version of acrylic pieces. I'll need a file they can work with, that I don't know yet.
I stenciled out the parts on poster board & used  some of the measurement's posted by lespaceplie, then cut out the fin.


I stenciled the fins & used compass to make the disks. I found you have to be accurate with all your pieces or it won't be level or fit correctly. The fins don't touch the center rod & the bottom parts stick out the edge of the handle.


Putting the fins & disk together is a first, then slide on to the rod, then adjust the fins & disks level with the handle.

WOW, you've done a great job on this, even with just the cardboard it looks good, can't wait to see it when you have the proper bits. Well done.

The lights set up was a great idea as well.

Chris.

I just made the hustler clip form some scrap metal from an old reclining office chair.
I had to grind down the rust & glue to make it reasonably shiny. Cut it then spray paint it with rustoleum silver paint.  
After a few Booboos I now know, make sure your done cutting before painting, because the heat from the the dremel will melt the paint, & I had to re sand & paint. ( I tried using tin snips but the scissors left divots in the metal which I had to smack flat with a hammer.)

I used a poster board diagram to measure out  the length of the entire clip & marked out the folds. (About a 9" strip.)

If you bend it around a piece of 1/8th or 3/16 rod/bolt or drill bit you will get a better bend at the mid point. Just a tip I though I'd mention as Ive made similar clips before.

It's looking great by the way, coming along nicely.

Chris.

Great advice on bending that clip, Chris. That's something I never would have thought of.

Quote from: elkad on Feb 21, 2017, 06:10 pm
(I tried using tin snips but the scissors left divots in the metal which I had to smack flat with a hammer.)

And more good-to-know notes on cutting metal, elkad! Those divots can tear clothing and cut skin, so cutting with a Dremel sounds like the safer way to go... remembering to use eye protection, and ear protection if the cutting is loud.

That clip looks pretty darned nice as you've made it. And because it bolts on, you can always keep your eyes out for a scrap strip of aluminium to make an upgrade to the clip. This way you can have a metal clip that's silvery, won't rust, and won't have silver paint rub off on anything.

Still, I think you've done a magnificent job on this one, clip included!

Dino.

Found the acrylic website. I forgot I put the link on my USB flash drive.

Anyone who needs laser cut acrylic in specific orange pink highlighter red whatever color, go here. http://www.tapplastics.com

More specific, here: http://www.tapplastics.com/product/plastics/cut_to_size_plastic/acrylic_sheets_transparent_colors/519

Quote from: elkad on Mar 03, 2017, 10:54 pm
Found the acrylic website. I forgot I put the link on my USB flash drive.

Anyone who needs laser cut acrylic in specific orange pink highlighter red whatever color, go here. http://www.tapplastics.com

More specific, here: http://www.tapplastics.com/product/plastics/cut_to_size_plastic/acrylic_sheets_transparent_colors/519

Thanks for the link  

Made a quick update video.


https://youtu.be/vWNMIuWVFT0?list=PLszC8lLG9th2HMqY-fLKZniMQFejT6CJC

Elkad, again your build looks outstanding, but would you please post the URL to the YouTube video so I can see this creation in action?

As a side note to others posting links between the [ youtube ][ /youtube ] brackets for the embedded player, would you also include the URL? Something within the last week or so has gone wonky and all I'm seeing with the embedded player is this:

Nothing to click on, nothing to see: so I'm missing out on all of the great work everyone is putting into their builds and the videos they're posting to showcase their great work. So including the URL with the embedded player would be a huge help for me at the moment.

(I don't know why this is happening. All of my stuff on my computer is updated, and this started before the update so I can't blame the problem on the updates. In fact it's usually my flash player going out of date that causes this, but I've got the current updates installed, and the above problem is still there.)

Dino.

I just watched this with no probs, mmmmm Gremlins are getting to everyone for different things on here. :-/

Chris.

The biggest problem I have in making props is space. I live in, (dramatic sting music), the mess.
I ask time & time again were I can put there stuff, no answer. So, I took out a bunch of stuff in a corner of the house, set up a chest of drawers to put my stuff in, so I CAN find it later.
I put my foam cuter on the drawers & started cutting the disks for my movelon gun. I found problems on my first cut.



First, slow cutting, the 12v transformer overheats fast & have to  take a brake on each cut, difficulty braking the cut. I broke the line on one of my disks wile braking what I thought was a clean cut. (Theses cuts are just melted lines you have to brake carefully, a crack can spread to another piece.)



After a few cuts, just to get them separate from the plastic panel, my wire burnt out & broke, pushing it to hard. (what size thickness wire is recommended for cutting, I forget the sheet thickness, plastic sheet?)



I have to cut the rest out with my dermal. (Save the cut pieces for possible other projects.)



I suddenly remembered a crucial point on making donut like disks, cut the inner hole first, that way the ring won't brake. (Less to hold on to if you start on the outside first.)
As for the fins, I found a colored plastic container allot longer than the last container & can handle two fins templates. I bought 4 containers, all a $1.00 each.

Quote from: elkad on Jul 22, 2017, 03:11 pm
I suddenly remembered a crucial point on making donut like disks, cut the inner hole first, that way the ring won't brake. (Less to hold on to if you start on the outside first.)

A good example of how people do what feels best to them. If I was going to cut out discs like this, I would use different sized hole saws and a variable speed drill (this way I could control the speed of the drill so it wouldn't go too fast and melt the plastic). I'd cut out the outside first, which would leave the center with a drill bit hole in it to mark the center, and then use that as the guide for the smaller hole saw for cutting out the center of that donut.

True, there would be less to hang onto, but if you could clamp the outer disc in a vice (using blocks of wood so the "teeth" on the vice didn't damage the plastic), then the vice could hold the outer disc steady while the smaller hole saw cut out the center.

(I would only do it like that because I hate the smell of burning plastic. It reminds me of those times on my ship when the cooks in the galley wouldn't change out the oil in the deep frier often enough, and anything they deep fried smelled like burnt plastic... and sometimes tasted like it!)

Dino.

Quote from: galacticprobe on Jul 23, 2017, 04:18 am

Quote from: elkad on Jul 22, 2017, 03:11 pm
I suddenly remembered a crucial point on making donut like disks, cut the inner hole first, that way the ring won't brake. (Less to hold on to if you start on the outside first.)

A good example of how people do what feels best to them. If I was going to cut out discs like this, I would use different sized hole saws and a variable speed drill (this way I could control the speed of the drill so it wouldn't go too fast and melt the plastic). I'd cut out the outside first, which would leave the center with a drill bit hole in it to mark the center, and then use that as the guide for the smaller hole saw for cutting out the center of that donut.

Dino.

You can also get the "Multi blade" hole saw that has one main housing for holding the different blades, that slot into the housing. You could use two hole saws at the same time, cutting the center as well as the outside. Haven't tried this yet myself, so don't know if it works. Just a thought though. Could try with some thin MDF first to check.

Chris.

I cut out the center of a new disk to replace the broken one using a small tool for scraping metal shaving off cut metal.



I sand down the disk edges & started on the fins.



I cut the fins out,..badly. To keep plastic from spiting all over the fins, I'll have to grind them slowly. (I can't use a small hack saw, it'd pull on the thin plastic pulling & braking it in half.)

I still can't get my angels strait.



Cutting these fins are making my dremal cutting wheel look like it's covered with cotton candy.

I eventually got back to finishing my prop. I wanted to show you how far I could sand & buff acrylic, with the budget I have.



Putting this prop tether is like putting a 3d puzzle together.





I had no stand to put it on so I made a makeshift clamp thingy using a vice & a C clamp.