FG42: First production model: In pictures

Battle Rifles, Custom builds, FG42, Products, Weapons, WWII

Airsoft replica of the WWII German battle rifle used by Paratroop units. The Fallshirmjägergewehr 42 was designed to give paratroops more firepower than their the standard rifles and SMGs as well as giving them a small enough package to jump with rather than having to drop them separately in a canister.

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This airsoft version is based on a later pattern, with only full automatic functionality. Semi-automatic functionality may be achieved with the addition of a mosfet or rate of fire control unit. 

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The bipod locks up and down solidly with knurled thumbscrews, as does the foresight unit. 

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This will come with a rubber bayonet, modified from a MAS36 but which maintains the look of the original.

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This replica takes standard TM/CYMA M14 magazines for ease of procurement, inserted in reverse. The version customers will receive will also have a false fire selector that is missing in this picture.

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The charging handle can move, the current design is not sprung but I hope to fix this in future versions.

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I have been asked a few times if I will be producing an early pattern FG42. Within a few months I will be producing a conversion kit with additional parts to make it into an early pattern for those who want it.

 

You can see the build process for this here and order the FG42 and many of our other items through Etsy.*

For large items like this, payments in instalments are welcome. Please get in touch to arrange.

*At present Etsy are being awkward about selling replica firearms. Please get in touch directly on enquiries.vintageairsoft@gmail.com to place your order

FG42: First production model: Improvements

Battle Rifles, Custom builds, FG42, Weapons, WWII

First things first, a locking system for the bipod. It flopped around a lot on the pre-production version so I have added locking lugs. This should hold it in both deployed and carry positions.

The new receiver and trigger group. The shape has been changed significantly, losing the fore-end entirely which allows for a much stronger wood fore-stock. The back has been extended to fill out the buttstock and support it fully.

The pistol grip has also changed to fit the new grips I am making.

I bought in some repro grips from the US and modified them with polymorph to fill in the air gap and make them really solid.

I then made rubber moulds of these modified grips and poured copies.

The new magazine well is a big improvement. It locks up very tightly on the magazine.

I have modified the Sten barrel to fit an extension. The gas port is welded directly onto the receiver.

The new foregrip in place. This is much more solid than the first version and will have a correct-looking curve across the top.

I sanded down the woodwork and stained it. Finishing it with hardwax oil.

I then cut a slot matching that in the receiver up into the gas tube for the operating handle in order to allow it to move.

Some of the new parts having their first coat of paint. I’m looking into 3D printed versions of some of these, but need to test out the strength of the parts.

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In position on the gun. 

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The bipod locked down, so far, so good!

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The new gas tube cover.

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There are a few other small changes, but this article covers the vast majority. I hope to have the first  production model completed this week!

 

If this build is of interest to you, please get in touch at: enquiries.vintageairsoft@gmail.com or join us on our Facebook page. Don’t forget you can buy our complete products via Etsy.

PZB 39: Build 3

Anti-Tank, Custom builds, PZB-39 Rifle, WWII

The basic components for this build are all in place, now it is time to add in the parts that pull it all together.

Next up was to fit the buttplate, the top half of this is fixed in place but the bottom folds in to help the rifle pack up smaller for transport. 20161129_141747

In the folded position. Once the cushioned pads are in place it won’t fold quite as far as this but it allows it to fold a lot closer than it would otherwise.

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I have now planed the stock down to its rough shape, adding the grooves with the router. If I was doing this again, I would definitely make these grooves sooner as achieving a straight and level cut on this shape is quite tricky!

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The forestock needs another mounting point further back to really solidly hold it in place, I expect I will have to make some kind of band that slips around the action as the bottom of the tubes at the chamber end are all cut open to hold the airsoft parts. It may make sense to combine this with the rear sight, which is still yet to be mounted.

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The rear sight fitted in position. This is welded into place on the front. I decided not to use this at the attachment point, instead adding a second screw well behind the first one.

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Taking the buttstock home, there are a couple of bits of fabric work for this build. Firstly, the leather cheek rest, presumably added to keep the cheek away from cold metal. It certainly doesn’t provide any great cheek weld.

The second part is the cushioned buttpad, to absorb the not insignificant recoil on the original!

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The leather cheek rest is laced on so it can be removed easily. The originals were sewn on but this looks the part and makes it easier to remove and maintain.

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I have to make the carry handle covers, fit the foresight and re-assemble to paint it, but that’s the majority of work to come.

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In the meantime, the trigger unit cover and pistol grip. I already welded the grip together, at this stage I used a bolt to line up the hinge points and the grip over the cover plate. This can be tacked down so the whole unit swivels as one.

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In place. The receiver was slightly out of square, so I used a clamp to hold it in place while I made adjustments.

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Although the pivoting grip unit doesn’t cycle the action like the original, it will be useful for disassembly.

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It opens much like the original.

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At the front, I now have a cover plate for the magazine well, which can be swivelled aside to access the magazines and change them.

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If you are interested in this project or have an idea of your own, drop us a line on enquiries.vintageairsoft@gmail.com to discuss. ‘Like’ our Facebook page or follow the blog to get regular updates on projects and interesting videos and articles. 

Don’t forget you can buy our complete products via Etsy.

PZB-39: Build 2

Anti-Tank, Custom builds, PZB-39 Rifle, WWII

The next step is to make the new bolt action. This allows the bolt to be used without cutting out a section at the side of the receiver.

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The front section locks the breech and operates the out of battery safety. The knob at the back keeps this in place and allows the user to grip the bolt to operate it.

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The receiver of the donor rifle (a VSR clone)  screws into the receiver of the rifle.

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The top of the receiver is welded in place, as are the thick back parts of the barrel. These also support the weight and hold the position of the internal parts.

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Slowly, I add on the rest of the barrel. To simulate the tapered barrel of the original I am stepping it down slightly along the length at opportune positions.

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This thing is now huge. It is already longer than the G98, even without the buttstock attached!

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The next job was to rough fit the woodwork. This is always very challenging, especially for the VSR rifles.

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Apologies for the quality of the pictures here, my camera was out of action so resorted to the ‘phone!

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This is important, the carry handle makes something like this just about portable.

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I bent two pieces of steel to shape by hand, two screws hold them together at the top. I will temper the steel so that it is stiff enough to hold the weight of the gun.

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And the buttstock is screwed into place. I will be modifying the top screw so that the stock can be folded and unfolded easily.

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The next few steps are to shape and finish the woodwork, screw said woodwork into place and mount the bipod, foresight unit and buttstock lock.

In the meantime, I am looking forward to getting this finished, it’s making my gun rack look comically small!

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If you are interested in this project or have an idea of your own, drop us a line on enquiries.vintageairsoft@gmail.com to discuss. ‘Like’ our Facebook page or follow the blog to get regular updates on projects and interesting videos and articles. 

Don’t forget you can buy our complete products via Etsy.

Gewehr ’98 Part 4

Custom builds, G98, Imperial Era, Rifles, Weapons, WWI

I used an epoxy putty to fit the buttplate due to the awkward shapes involved.

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I also replaced the bolt handle, which had been secured with a small M3 screw which wasn’t solid enough to endure repeated use. Now it is secured with an 8mm plug and pinned in place. It is now also steel, so it shall wear better and keep its colour.

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I also replaced the front band/bayonet lug with an original, stainless steel one.

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Pretty well finished now! Just got to put the band and top hand guard back together. Completed pictures to follow.

 

If you are interested in this project or have an idea of your own, drop us a line on enquiries.vintageairsoft@gmail.com to discuss. ‘Like’ our Facebook page or follow the blog to get regular updates on projects and interesting videos and articles.

You can also buy many of our finished products in our Etsy store.

FG42 Pre-production prototype complete

Battle Rifles, Custom builds, FG42, Weapons, WWII

Long-awaited by many, the pre-production FG42 is now finished!

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This airsoft model was designed with a number of considerations in mind:

  1. It should be relatively affordable. Obviously work like this is expensive but the price should be kept as low as possible.
  2. It should use standardised airsoft parts as far as possible to allow for upgrade and tech work to be carried out with relative simplicity if/when it must be carried out.
  3. It should use standard magazines. Airsoft guns with dedicated mags for a relatively niche audience become unusable if the magazine malfunctions or breaks.
  4. It should have features as authentic as possible to the original.

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After several years of work, this prototype which roughly shows what the end product will be like. This is NOT the finished product, there are a number of design and manufacture differences that will be implemented in future models:

  • The pistol grips will be replaced with a design that is both easier to make and more authentic
  • Gas port detailing will be improved
  • The forestock will be re-designed: So that the operating handle will move and the shape of the woodwork will be improved
  • Bipod: locking mechanism to improve stability when in use
  • Add turf spike to bipod
  • Improve case deflector
  • Improve aesthetic of rear sight
  • Improve access to hop adjustment
  • I hope to produce a bayonet for it in time (such use as it may be!)

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There are a number of positive features of this design which I shall be retaining however:

  • The base gun is an AEG airsoft Sten, taking upgrades for this model and having its excellent hop-up
  • The magazines are standard, unmodified M14 midcaps
  • Both fore and rear sight fold down for transport
  • The rear sight adjusts for elevation just like the original, you can see a video of a prototype here
  • The construction is, as far as possible, steel. The woodwork is laminate, like the originals (so far as I can gather)

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If you are interested in this project or have an idea of your own, drop us a line on enquiries.vintageairsoft@gmail.com to discuss. ‘Like’ our Facebook page or follow the blog to get regular updates on projects and interesting videos and articles.

 

You can also buy many of our finished products in our Etsy store.

FG42: Part 6

Battle Rifles, FG42, Weapons, WWII

Through all this section I am working in the background on the furniture, staining and varnishing it for use. This is literally watching paint try so I will just give you an intermediate shot of the process rather than bore you with a step-by-step!

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There aren’t any good photos of the bipod in progress, each fold was handmade in the vise with a few different hammers and other tools until each was at the right angle. For a production version, these will probably be made with a press if I find a supplier who can do this.

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And folded away! This should really look the part when painted up and the furniture is in place.
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Next, shaping the grips. I used polymorph plastic coloured with acrylic paint as a base colour. These are just a rough first pass, they will be re-shaped with a heat gun to get a smoother finish.

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After a bit of work with the heat gun and some tools, the finish is now quite smooth, providing a good base for etching in the chequering.

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I oil backed the rear sight for a really wear-resistant finish. As with previous versions, this adjusts just like the original.
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On the lathe, I turned the muzzle brake in plastic. When this is finished I shall produce a mould to cast more from as it is quite a complex piece.

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I made a mould and took a casting from it. This has been painted up to look like metal!

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And this slots onto the gun! Oh yes, I have now oil finished the foresight unit and bipod, which should resist the wear and tear that will inevitably affect these parts better than paint.

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Pretty much all there at last! Just a few last details to finish off…

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Completed pictures to follow.

 

If you are interested in this project or have an idea of your own, drop us a line on enquiries.vintageairsoft@gmail.com to discuss. ‘Like’ our Facebook page or follow the blog to get regular updates on projects and interesting videos and articles.

 

You can also buy many of our finished products in our Etsy store.

FG42: Part 5

Battle Rifles, Custom builds, FG42, Weapons, WWII

Since the last post, I have attached the new magazine well, it’s not looking pretty yet but is feeding from the magazine! At this stage function> appearance, though it’s not long before it looks right and actually works.

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My second model bipod legs, these are much thinner and lighter than the first attempt but are the same basic shape. However on completion I found that they interfered with the barrel. Not a problem though, a new design is due from the laser cutters any day now.

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The bipod mounting unit and foresight unit is going to be one part.

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The foresight mounting block, which incorporates the bayonet mount, barrel lug and front sling mount.
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Roughly cleaned up, this will get some attention from the scotch brite pads before finishing.

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And in place on the barrel, the foresight can be folded down for transport. The screw will be replaced with a knurled head screw to lock it in place.

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Next, I secured the buttstock in place. A piece of polymorph prevents the wobble of this piece, I plan to make a front cover to hide the gaps. On the production version I will tweak the design to sit closer to the receiver naturally.2

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At the front end, the fore-stock has been screwed into position around the cocking handle. This one has been welded into position, in time I hope to produce a version that has a moving cocking handle but at present this is where the battery goes.

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So finally we can now see the overall format of the FG42! The sling is from Zib-Militaria, it is effectively identical to an MG34 sling. The metal parts look as though they have been painted while still rusty so I won’t be providing these to customers.

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Not far off now!

  • Details like the selector switch, pistol grips
  • Stain and varnish the woodwork
  • Flash suppressor
  • Gas tube/battery compartment cover

And of course overall paintwork etc…!

All that to come in the next instalment.

If you are interested in this project or have an idea of your own, drop us a line on enquiries.vintageairsoft@gmail.com to discuss. ‘Like’ our Facebook page or follow the blog to get regular updates on projects and interesting videos and articles.

You can also buy many of our finished products in our Etsy store.

PZB-39: Build 1

Anti-Tank, Custom builds, PZB-39 Rifle, Weapons, WWII

After some extensive design work, laser cut parts and some timber start off the build!

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I started by bending the buttplate components. Part of this folds down to make a more compact package. I designed this with tabs and etched lines to make folding as precise and easy as possible. I could then weld the parts in place to maintain they shape and increase the strength of the parts.

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I then welded the inner pieces of the receiver and the buttstock hinge unit.

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This pivots to shorten the length of the weapon to make it *slightly* more portable, such as anti-tank rifles ever are.

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A piece of steel tube makes the rest of the back of the unit. It will be welded onto the top part of the buttplate. Here you can see the outer plates of the receiver in place, which stops the stock from folding up over the gun when in use.

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The pistol grip and trigger guard unit. In the original this is used to open the breech and eject the spent case. In this version sadly it won’t be possible to do this, but it will be used for disassembly.

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For the front end, the bipod unit is coming together, to keep it light and strong the legs and feet are thin gauge steel plate, folded and welded into shape. These will then be attached to the hinge which is thicker steel for strength.

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If you are interested in this project or have an idea of your own, drop us a line on enquiries.vintageairsoft@gmail.com to discuss. ‘Like’ our Facebook page or follow the blog to get regular updates on projects and interesting videos and articles.

You can also buy many of our finished products in our Etsy store.

FG42: Part 4

Battle Rifles, Custom builds, FG42, Weapons, WWII

The next important step In making the FG42 was the furniture. The prototype served its purpose but it was time to get something that was a better shape. I took the outside shape and created a series of layered profiles that could be glued together. These were then laser cut in plywood.

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I put two pilot holes in the backs to line them up, using M4 screws. Then put each layer down in order with a thin coat of wood glue and clamped it.

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The two halves could then be glued together. Here’s a picture of the new next to the old, as you can see the shape is much improved and the sling swivel mount is present in the new version.

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For the fore-end, much the same procedure was followed, I’m concerned about the strength of this part as there are some very thin joints so this may have to change for production. Nevertheless, the original was fragile so maybe this is authentic!

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I took the worst of the edges off with the draw knife, but it was quite difficult due to the perpendicular grain.

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In the end, I switched to the drill mounted sanding drums, which dealt with the cross grain far better and gave a relatively smooth finish. A quick going over with sandpaper by hand will clean this up nicely.

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Not looking too shabby though I say so myself! A bit of wood stain and some kind of epoxy outer should finish this off nicely when it is sanded down. The next step is to make the new magwell and create the bipod!

 

If you are interested in this project or have an idea of your own, drop us a line on enquiries.vintageairsoft@gmail.com to discuss. ‘Like’ our Facebook page or follow the blog to get regular updates on projects and interesting videos and articles.

You can also buy many of our finished products in our Etsy store.