DIY GBB cylinder alu casting ?

[MultipleParadox]

Hey guys,
as some of you may knows from another thread, my KWA M93r's cylinder broke. I ordered 2 from ebay, to have a spare one as it seems a common issue with that part.

So since there's no aftermarket, more resistant version of that part, I was considering the idea of using one of the spare cylinder as a mold positive to create a negative and cast it with aluminum...

I personally don't have any experience in casting and mold making, but I'm the kind that love to learn stuff. But I was wondering if anyone here have an opinion about this?

Considering it'd be well made (hopefully), do you think it'd last? Or is the alu on alu (slide is aluminium too) would create too much friction? Or is casting prone to breaking too much?

Basically, I'm asking in order to know if it worth the time and effort to go and try that. To anyone has experience with that kind of part, and/or casting, let's hear your voice

Thanks


MP

[Styrak]

I think cylinders/pistons/loading nozzles (whatever you want to call it) are made of plastic for a reason.

[Rugger_can]

Casting very small parts is very difficult and using simplistic alloys you could buy would result in a very weak part with low tensile strength.

I'd have to agree with Styrak, Plastic is probably used for a reason. Are they breaking very often? I mean at 10 bucks if they break once every 2000 rounds it might not be a big deal.

Cheers

[MultipleParadox]

You're somewhat confirming what I thought, despite the fact I was hoping for a different answer :P

They do seem to be breaking quite frequently, as there seem to be a lot of thread regarding that very part on the web...

It's not expensive, it's more a matter of trying to get free of the hassle of ordering and waiting for that part... Because of that I'll probably have to leave my sidearm at home for my first game, it's quite disapointing, but it's life

Thanks for your inputs

[Rugger_can]

You COULD consult a professional casting company and see about getting a small run done in a stronger material or using a stronger self lubricating plastic.


Just a final idea.


Cheers

[MultipleParadox]

Originally Posted by Rugger_can

You COULD consult a professional casting company and see about getting a small run done in a stronger material or using a stronger self lubricating plastic.


Just a final idea.


Cheers

I guess you're right, but i also guess it'd cost a whole bunch of money I'm probably not willing to put... I'll patiently wait for my replacement parts to arrive

"Home casting" seems a fun hobby though, maybe I'll give it a try, for other purposes, eventually :P

[ILLusion]

How complicated are the features of the part?

It would be stronger and cheaper to machine the part from aluminum billet, rather than to cast them from aluminum.

An aluminum die-cast mould is FAR from cheap, and is better suited for high volume production runs. Hand machine it if you'd like to do it cheaper and to get a stronger part.

[Rugger_can]

Originally Posted by ILLusion

How complicated are the features of the part?

It would be stronger and cheaper to machine the part from aluminum billet, rather than to cast them from aluminum.

An aluminum die-cast mould is FAR from cheap, and is better suited for high volume production runs. Hand machine it if you'd like to do it cheaper and to get a stronger part.

It could be machined, it would be a time consuming run but it could be done. But it would have to be CNC'ed or you would have to be an amazing machinist to do that by hand. Good call though, did not even think of suggesting that.


Also, you could have a run made and sell them. If it's a common issue you might be able to wholesale the lot to a company. Could be a business venture.

Cheers.

[Dynamo]

if it's a simple cylinder/piston type of deal, i could machine it. i would need either the part it self or really accurate measurements. if you lived in Toronto, i could pick up the parts and have the finished parts done and back in your hands before the end of the day.


****

Originally Posted by Rugger_can

It could be machined, it would be a time consuming run but it could be done. But it would have to be CNC'ed or you would have to be an amazing machinist to do that by hand. Good call though, did not even think of suggesting that.


Also, you could have a run made and sell them. If it's a common issue you might be able to wholesale the lot to a company. Could be a business venture.

Cheers.

if thats the part, then well casting is really the only option. could sand cast the outside profile and then machine out the inside.

[MultipleParadox]

Originally Posted by Dynamo

if it's a simple cylinder/piston type of deal, i could machine it. i would need either the part it self or really accurate measurements. if you lived in Toronto, i could pick up the parts and have the finished parts done and back in your hands before the end of the day.

I thought about machining the part as it'd be much more resistant, but quickly dismissed the idea as I thought it'd be way too expensive, but now that you put it that way...

I'm waiting for two cylinders, if you're into machining these, I could send you one of them for the time it need. Shipping in an enveloppe would be pretty cheap anyway.

I guess you wouldn't do this for free, what's the price range I should expect?

I'll ask KWA first if really it's a good idea to have an aluminium cylinder though, as there might be too much friction like stated above.

Thanks!

Edit: oops, just read your edit after i submit :P hum that would increase cost having two processes I think. Then again, the inside is mainly hollow with nothing more than a groove or something... Would keep machining simple

[ILLusion]

Originally Posted by Rugger_can

It could be machined, it would be a time consuming run but it could be done. But it would have to be CNC'ed or you would have to be an amazing machinist to do that by hand. Good call though, did not even think of suggesting that.


Also, you could have a run made and sell them. If it's a common issue you might be able to wholesale the lot to a company. Could be a business venture.

Cheers.

That part does look more complicated than I'd thought. Hand machining won't be easy, but it won't be impossible, either. I can see why the company decided to manufacture this part from shot plastic, though.

Again, due to the high cost of CNC setup fees, going the CNC route isn't worthwhile unless it's for a large production run. With that said, creation of high quality die cast moulds generally involves CNC as well, which is part of the reason why casting moulds are so pricey. For parts this small and with walls so thin, it's actually better to stay with plastic - or at least a stronger one. Something like Delrin would be a great material for parts like this.

If you can find a skilled machinist, it wouldn't be impossible to get such a part made by hand. If you're looking for just a couple of units done, the bottom line price would be cheapest via hand machining, but will still be rather expensive on a per unit cost basis.

[MultipleParadox]

About mould, that's the reason I was considering the DIY route. I'm well aware it's probably not an easy matter, and would need a lot of correction through polishing and what not.

But I think it'd be possible to create a mould from clay using the plastic part, creating a solid piece having the exterior profile, and then finishing the inside on a mill or something.

Edit: might be overkill, but a press-drill, vise and dremel might even do the thing, but probably time consuming...

[ILLusion]

Originally Posted by MultipleParadox

Edit: might be overkill, but a press-drill, vise and dremel might even do the thing, but probably time consuming...

Nerves of steel and the steadiest hands in the world would probably help as well. LOL

[MultipleParadox]

Originally Posted by ILLusion

Nerves of steel and the steadiest hands in the world would probably help as well. LOL

Or clamps and vise to compensate But yeah :P

[Styrak]

Originally Posted by ILLusion

That part does look more complicated than I'd thought.

Illusion, it's a GBB loading nozzle/piston. Sounds like you didn't know what he was talking about. (although he says in the first post )