Happy Trooper DLT-19 $50 Hardware Store Build

[greenyone]

I'm sure this one has been done before but I thought I'd add my take on it.

This is obviously a budget build.  I was able to source most of the materials at Lowes.  The parts and tutorial are here:  https://happytrooper.com/?p=5594

His tutorial really only requires a few hand tools, a jig-saw and a drill or Dremel and the ability to print out his supplied pdf templates.  I'm fortunate enough to have access to a desktop CNC router, so my build differs from his a bit.

First step was to download the templates.  They are offered in .svg as well as .pdf.  My first attempt at using his .svg files with my cad/cam program resulted in a receiver that was big enough to satisfy Hulk sized hands.  I guess the scaling didn't translate well between whatever he used to create his files and the program I use.  So just be wary of those .svg files if you go the same route as I did....they may need resized.  I printed out the .pdf's in 'actual size' (which looked a bit more realistic than what I was seeing in the .svg's).  That allowed me to take some measurements on the paper version to apply to the cad vectors.

 

   

 

[greenyone]

Happy Troopers tutorial calls for using some small metal brackets to attach the PVC parts to the wooden receiver.  That involves drilling holes in the sides of the PVC couplers and tube to accept some screws, followed by using some putty to cover the screws once installed.  I opted for a different approach which involves cutting some discs to fit and be bonded inside the pvc parts.  No external screw holes to hide with putty this way.

 

[greenyone]

Fits nicely in the hand.

 

[greenyone]

Mock-up with the barrel.

 

[greenyone]

Something I did not show in earlier posts....but when I imported the .svg files in my cad/cam program I added some 1/4 inch locating holes in the wooden parts.  As these are cut out then sandwiched together in layers, the holes with dowels inserted make lining things up a bit easier when gluing & clamping them together.

 

[greenyone]

Happytrooper includes a template for the pvc parts as well.  Those come in handy.  For the barrel you simply wrap the printed template around a 2 foot store bought piece of 1-1/4 diameter schedule 40 PVC pipe.  This gives you not only a length cut guide, but also markers for the barrel holes.  A drill press makes this a bit easier but a hand drill would get the job done too.

 

[greenyone]

For the inner barrel Happy Trooper uses tape wrapped around the wooden dowel to center it within the outer barrel.  I went back to the CNC machine and cut some rings that will accomplish this without the use of tape.

  One on each end the barrel should get the job done.  On final assembly I'll use more PVC cement to keep these in place.

 

[greenyone]

Still a lot of wood shaping to do, but here are the majority of the parts dry fit together.

 

[greenyone]

Here is an option.  Rather than using a mouth wash cap, these conical shaped rubber crutch/cane ends fit the diameter of the inner barrel....and provide a nice solid point for when you have the rifle resting on the ground.

 

[greenyone]

Getting paint sprayed inside the outer barrel would be next to impossible.  Here is a neat trick for dyeing white PVC pipe.  An ebay dye combined with clear PVC cleaner to stain PVC instead of painting it.

https://www.ebay.com/itm/Black-Dye-for-PVC-STAIN-1-4-oz-concentrate-MAKES-4-OUNCES-STAIN/262496988014?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m2749.l2649

 

 

 

[greenyone]

Sand, apply general purpose putty, sand-sand-sand, prime, sand, spot putty, sand sand sand.

 

[clayorrnot]

I'm trying this build right now too. Going to see if I can make a found item scope to go on top to make a dlt-19x. Planning on documenting my progress. This looks good man, keep up the good work!

[greenyone]

9 hours ago, clayorrnot said:

I'm trying this build right now too. Going to see if I can make a found item scope to go on top to make a dlt-19x. Planning on documenting my progress. This looks good man, keep up the good work!

It's all pained and assembled.  I may come back at some point and add the bi-pod, but I kinda like it the way it is for now.

I put this together with as may things I had on hand or from scrounging to keep it cheap cheap cheap.  For instance.  I already had a can of satin black rattle can paint, some of the PVC, the wood was left over from a shelving project.  The plastic for the grips and greeblies is .125" black textured ABS that I had from a car stereo install.  The inner barrell is actually an old walking cane cut to size.  My bought items were largely just the hardware and bondo putty.   Of course I have a hobbiest desktop CNC machine that probably made this considerably easier than using a jig or scroll saw, but overall this is very easily do-able for not much money if you are resourceful.

 

 

Here are some photos:

 

[Aradun]

Nice work Kurt!  Can’t beat the price either.  I did this build about two years ago with some modifications.  I didn’t take too many photos of the build process but I’ll dig up what I have and try to post them.  I know I made the body a little different from Happy’s directions.  I used two stair treads that I had lying around, which gave me the perfect width When compared to real blueprints of the mg that I found online.  The blue prints enabled me to fine tune the build to get it to proper scale.  

[Aradun]

So as not to highjack your build Kurt, I posted my photos under a separate post.

http://forum.501stpathfinders.com/index.php?/topic/21195-dlt19-happy-trooper-build-with-mods/

[Hiker Scout]

Did you use 2 1" pieces of wood for the body as well or just the stock?  And kept the 3/4" pices for the main body?

What was the final weight of the build? 

 

Im debating the DIY version versus a 3D printed one.

[Aradun]

I can tell you I used two 1” pieces of wood for the stock and body. I added wood block where needed with bondo to shape the pieces. Not sure of the exact weight but it has some serious heft to it.

[TK7892]

This is absolutely incredible work! If I had the tools and the time I would try taking it on myself!