SCAR for Everyone, How to build your very own FN SCAR-L (Tutorial Part 2) [Archive] - OSW: One Sixth Warrior Forum

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PemGreene
07-24-2007, 12:51
Next part of the construction is the upper receiver. We start by taking 6x6 mm square rod of styrene and cutting it to the length of the upper receiver in the picture.
https://www.onesixthwarriors.com/photo/data/501/2Pic001.jpg
Then we super glue a piece of 1 mm thick sheet of styrene to one of the sides. This side will become the side with the shell ejection port on it.
https://www.onesixthwarriors.com/photo/data/501/2Pic002.jpg
When dry we then cut off the excess and file smooth with the square rod.
We then measure where the ejection port would be and cut through the 1 mm thick sheet of styrene and pill it off.
https://www.onesixthwarriors.com/photo/data/501/2Pic003.jpg
File the sides of the opening straight. Now we will glue a piece of the 1 mm thick sheet of styrene sideways on the bottom of the port so that the 1 mm part is super glued to the upper receiver. Then glue another piece of 1 mm thick sheet of styrene 2 mm above the sideways piece.
https://www.onesixthwarriors.com/photo/data/501/2Pic004.jpg
Now cut and file the sideways piece until it is flush with the rest of the upper receiver.
https://www.onesixthwarriors.com/photo/data/501/2Pic005.jpg
The upper rail is next. We start by cutting 2 strips of 1.5 mm thick grooved sheet of styrene where the cut is across the grooves to make the rails. Also, cut a piece of 3x3 mm square rod of styrene to the same length of the upper receiver and another a little bit larger (it does not matter how large the second one is).
https://www.onesixthwarriors.com/photo/data/501/2Pic006.jpg
Now glue the grooved pieces to the square rod, groove side up. I suggest clamping the one that is the length of the upper receiver and not the other (you will see why later).
https://www.onesixthwarriors.com/photo/data/501/2Pic007.jpg
When the glue sets file off the edges so that the grooved apart is flush with the square rod.
https://www.onesixthwarriors.com/photo/data/501/2Pic008.jpg
On the larger one peel off the grooved part and this will become the side and bottom rails (it is easier to peel off if you do not clamp when glued).
https://www.onesixthwarriors.com/photo/data/513/2Pic009.jpg
Now we are ready to glue the top rail to the upper receiver. We start by curving the top corners of the upper receiver.
https://www.onesixthwarriors.com/photo/data/513/2Pic010.jpg
Now glue the top rail to the upper receiver. You may need to file down the upper rail to have it match the size in the picture.
https://www.onesixthwarriors.com/photo/data/513/2Pic011.jpg
Next, cut about 1 mm wide strips in the 1 mm thick sheet of styrene. I use a razor blade to continuously score the section until I cut through. You will need four pieces for each side, one for each of the sections in the picture below and one that is the length of the upper rail.
https://www.onesixthwarriors.com/photo/data/501/2Pic012.jpg
https://www.onesixthwarriors.com/photo/data/501/2Pic013.jpg
https://www.onesixthwarriors.com/photo/data/501/2Pic014.jpg
Now we glue this strips above the upper receiver on the upper rail on both sides.
https://www.onesixthwarriors.com/photo/data/501/2Pic015.jpg
We glue the long strip above this on the upper rail.
https://www.onesixthwarriors.com/photo/data/501/2Pic016.jpg
File the strips until they are flush and look straight.
https://www.onesixthwarriors.com/photo/data/501/2Pic017.jpg
Now take some thin scrap styrene and glue the two thin separators in the front hole. Cut to size and file smooth.
https://www.onesixthwarriors.com/photo/data/501/2Pic018.jpg
Next, cut the rails for the side and the bottom to match the picture.
https://www.onesixthwarriors.com/photo/data/501/2Pic019.jpg
Glue a piece of the 1 mm styrene to the bottom rail and glue it to the bottom of the upper receiver. You can glue the side rails on now but I wait until after I put the body filler on.

We can now glue the lower receiver to the upper and we are done with the construction of the upper receiver.
https://www.onesixthwarriors.com/photo/data/501/2Pic020.jpg

Next we will construct the barrel. I start by finding the length I want. For this weapon I went with a 46.5 mm barrel but you can do any thing smaller then this. The barrel is made from two pieces of 3/32 inch styrene tube, a 5/32 inch styrene tube for the cover, a thing that is on the end of the barrel (I do not know what it called) from my parts box, and a 1/16 inch styrene rod. First I cut them all to length and use a drill and file to make sure they are straight. I put the tube in the drill and tighten the drill until it is snuggly secured (do not over tighten or you will leave marks on the tube or crush the tube). Then while the drill is spinning file the end of the tube.
https://www.onesixthwarriors.com/photo/data/501/3Pic001.jpg
https://www.onesixthwarriors.com/photo/data/501/3Pic002.jpg
Next take the 5/32 inch cover and saw a straight line through its length.
https://www.onesixthwarriors.com/photo/data/501/3Pic003.jpg
Now glue a scrap piece of 1 mm sheet of styrene in the line.
https://www.onesixthwarriors.com/photo/data/501/3Pic004.jpg
Next, we file the scrape piece down and glue the small 3/32 inch styrene tube and glue it to the top. If you want you can file a small grove in the front of the top piece.
https://www.onesixthwarriors.com/photo/data/501/3Pic005.jpg
The final step is to drill a 1/32 hole in the end of barrel thingy and glue a 1/32 rod in it.
https://www.onesixthwarriors.com/photo/data/501/3Pic006.jpg
https://www.onesixthwarriors.com/photo/data/501/3Pic007.jpg
Now we need to drill a 1/16 hole in the 3/32 top tube and glue a 1/16 rod in it. We drill a 3/32 and 1/16 holes in the upper receiver in the appropriate places from the picture.
https://www.onesixthwarriors.com/photo/data/501/3Pic008.jpg
https://www.onesixthwarriors.com/photo/data/501/3Pic009.jpg
Now we are done with the construction we can add the sight you want and connect it to the upper receiver. I do not glue it yet so that it is easier to use body filler and sand.
https://www.onesixthwarriors.com/photo/data/501/3Pic010.jpg
https://www.onesixthwarriors.com/photo/data/501/3Pic011.jpg