Kyle Katarn's Bryar Pistol

I was commissioned by gboy6 over at cosplay.com to make this pistol, providing this reference as a base:

Because the pistol uses an m16 grip, I grabbed one from my spare airsoft parts bin and scaled up the reference picture on my computer screen to match the size of the physical grip. I could then use the computer screen as a light table and trace more complicated parts, thus taking measurements in real size. I drafted directly onto the materials.

The main body is .75" MDF, made by joining a .5" sheet and a .25" sheet.

These are the basic parts for construction. The .75 MDF frame was perfect because it allowed the airsoft pistol grip to simply slide on and off, So alternative grips can be easily installed.

Refinement on the basic parts below. The ribs were a complete pain to do. (all parts care cut out by hand) Notice the notch that guides the pistol grip in. (had to be perfect)

Putting it together :

The side faces were coated in super glue, and thin sheet styrene was looped around the bottom to make the handguard. The styrene was then trimmed with a hobby knife, and sanded.

Since I decided not to make the trigger functional, and I did not want to make it the same thickness as the basic gun body (.75 inches thick) It had to be made separately and glued on after. Because of the direction of the MDF fibers, Simply gluing it on would probably not last long. I decided to pin it with a copper rod, so that it could hold up to being "tested" by other people who may hold the prop.

Just about ready to paint. Just some minor filling, and some barrel details left.

Did I mention how tedious it was to space those ribs out while they dried in place?

So begins the barrel details. (very time consuming) I constructed 7 little styrene boxes, then cut out the holes for them and inserted them until they were flush. It was difficult to get the superglue in-between the seams to hold them in.

Filler primed and sanded.

a few coats of flat black. Still waiting to hear back from the client about "battle damage" and such.

Got word back from the client about coloring, but not battle damage. did some metallic drybrushing here and there.