Team Fortress 2 Heavy Minigun Build (3D printed, IMAGE HEAVY)

[coryalex]

UPDATE


Correct belt size located... so, we're a "go" for Barrel assembly and testing (video at the end of this post)


In this update:
- barrel installation
- rear can installation
- installed threaded tee for securing rear hatch
- test of motors and LEDs (video)


Barrel is secured with a conduit coupling.
The barrel's conduit/shaft is drilled for a bolt to go through the coupling and through the conduit... with a jam-nut for security.

Belts run between upper and lower assemblies

Motor rig installed and wiring for LEDs, Motors, and Speaker run through wall between cans

Rear hatch installed

Progress so far (eye candy)

Brass Eject Cover is painted and assembled... just needs to be affixed to rear can

VIDEO of final barrel test

Next steps:
- install Brass Eject Cover
- install "wingnuts" on handle
- begin fabricating rear handle assembly/frame (with wiring)
- fabricate lower piping from lower rear box through ammo can nipple

 

[smoothrat]

Looking good, and making great progress.

 

[clancampbell]

This is beyond building, it's almost magic!!!

Truly superb

Rich

 

[coryalex]

UPDATE


Brass Eject Cover installed on rear can




Lower Pipe and Coupling installed from Rear Can to Ammo Can Nipple (PVC bent with heat gun)



Rear Handle/Frame constructed and ready for paint and wiring
(Square plate is a special bracket for the rear can I designed and printed)








Once the Rear Handle was constructed, I couldn't help myself... I had to pick her up and show her off




Next steps:
- coat rear handle/bracket assembly with Plasti-Dip (one coat brushed on, top coat sprayed on)
- thread wiring through rear handle/bracket assembly
- wire and install control box on rear handle
- attach wiring to electrical components inside rear can
- fabricate, paint, and install two cylinders (one for each side of the rear tube... where the "motors" appear to be on the model)
- make little babies cry some more

 

[coryalex]

UPDATE


Wiring has begun!
I decided to install the control box and run all wires BEFORE attaching the handle/frame to the prop.


First, I threaded the bundle of necessary wires through the frame




The control box is attached with Shoe Goo on both registers AND a carriage bolt and fender washer to the frame... not going anywhere



So far, I've got the following wired up on the controls side:
- Switch to wind up motors (also triggers "wind up" and "wind down" sounds)
- Switch to light the LEDs (also triggers "firing" and "spin" sounds)
- Switch to toggle betwen which "firing" sound is triggered by "FIRE" button... either normal firing or crits will be played, depending on switch position






Next steps:
- wire up remaining 4 sound trigger buttons on the control box
- install control box cover
- attach frame/handle to Sasha
- complete wiring of sound board, amp, main power cutoff, and batteries


I estimate I've got about 4 more hours of work left to complete this build (not including remaining items on the costume checklist... but that's getting close, too)

 

[coryalex]

UPDATE


Wiring of controls went relatively smoothly... control box works lights, motors, and all sounds

Wires run through frame and into the rear can

Here's a video of the sound demonstration (how sounds are triggered from the control box)

Next steps:
- protect metal edges of rear access hatch (I'm worried about sharp edges damaging wiring during battery changes)
- show off my finished prop (yeah, the minigun is technically finished... but I'm waiting until I get the rest of my costume done before doing a reveal video... please be patient, it should only be a couple of days)

I will post more complete photos and video of the finished prop when I'm really, really done.

 

[metal wood]

nothing i can say that hasnt been said all ready. just loving the crap out of this build!! keep up the inspiring work!

 

[Gixxerfool]

Quick question, your spinning down sound, how did you go about getting that to work? Do you have a separate master power switch and the larger toggle does selection? I have a power down sound that I can't use cause obviously it shuts everything down.

 

[coryalex]

Yes, there is a separate master power switch on the back of the rear can that controls the 12v and 3v circuits... The control box only triggers sounds and enables motors and lights. My proton pack is built the same way to allow me to use all sounds.

 

[coryalex]

Oh, I have a final weight for the finished prop.
Drum roll, please...
28.5#

I'm so glad I will be utilizing a harness under my vest to bear the weight.

 

[coryalex]

UPDATE

I was able to find a load-bearing belt to use with my Minigun.
I wanted to be able to carry her all day, every day for 3-1/2 days (Phoenix Comicon)... but I also didn't want my arms and back to break.
This load-bearing belt was found at a military surplus store for $16 (plus $7 for the pistol belt inside it).
I'll wear this belt under my shirt, hidden from view.


I also got labels done for the control panel (right hand controls) and the master panel on the back of the gun (main power switch and volume)... with a fun nod to my Ghostbusters friends.



I'm still working on the last bits of the costume before I do the final reveal... I want to do it right, so bear with me.

 

[coryalex]

UPDATE

I swear a reveal is coming... I've just been incredibly busy with family stuff this past week or so... please, bear with me.

However, I have created one more addition to Sasha. I felt the barrel lights needed something to help them look less like points of bright light.
So, I modeled little "explosions" or "flashes" in Sketchup and printed them in clear PLA.
These inserts will be removable (only held in with a dot of hot glue for the con)... and I'll only use them if the effect is good (and I'm hoping it is).
Here's what I modeled and printed...




I modeled it without a base at first, but then I realized a little flanged base would make it easier to install and uninstall.

Oh, I also made a 4xC cell battery pack for use with this prop as a backup for the Li-Po pack (in case it doesn't last all day).

Enjoy!

 

[Wreckhur]

I am at a loss for words. The way you solved all of your technical issues is quite simply brilliant. My hat off to you Sir on your breathtaking build. I can't wait to see the full reveal.

 

[coryalex]

I've decided to do a limited reveal of just the finished Minigun prop for this thread (photos and demo video)... I'll do a full "Heavy Costume" thread separately to showcase all the items I've crafted and assembled for this costume.

Photos and video coming tomorrow.

 

[metal wood]

opcorn

 

[coryalex]

UPDATE!!!

I'm finished with this prop... after 3 months of free time spent.
I had a LOT of fun overcoming challenges of this build.
Mixing 3D printing with some more traditional techniques was fun.

Here are some photos of the finished prop...

Here's a VIDEO of the finished prop in action...

I will be doing a full costume reveal in a separate thread when I'm done with that (I'm close on that front).
I figure that's more appropriate, even though I've had some bleed-over into this prop thread... I'm just so excited about this project.

I will be wearing it for the first time at Phoenix Comicon this June.
I hope to see some of you there!

Thanks for your kind words and support throughout this build!

 

[RobI]

That brings back memories! I remember playing Team Fortress 2 for HOURS and I rocked the mini-gunner. That is truly awesome.

 

[Gixxerfool]

Amazing build. You have plans to build a stand for it after the con? It would look great mounted and would keep the lower pipe from being damaged.

 

[coryalex]

... You have plans to build a stand for it after the con? It would look great mounted and would keep the lower pipe from being damaged.

Yeah, I'm going to wall mount using the eyelet I'm installing on the back side near the handle. That eyelet will be primarily used to attach her to a load-bearing belt to save my arms and back while costumed. The bonus use will be the ability to hang her on the wall when I'm done.

 

[FakeBritishAccent]

Wonderful work, sir.