In the comic books, Mara owns a collection of weapons that would make any pirate
jealous. Some of the weapons she is seen with include a BlasTech DL-44, a BlasTech
DL-18, a BlasTech E-11 Rifle, and a very small holdout pistol made to go in a sleeve
holster. She also has a square-nosed blaster that seems to be a favorite for the
various artists. This blaster goes in a holster on the back of her belt and I really
like the look, so I selected that blaster for my second Mara costume. Many Mara Jade
costumers use airsoft pistols for this costume prop, and I've seen some very close
approximations to it. I like to make things from scratch, however, so I set about
making a blaster of my own.
First, I looked for some good reference pictures. I found that the images of the
squared nosed blaster changed from book to book, from page to page... and that same
blaster even looked different in different panels on the same page! So, once again
I had to make my own interpretation of how the various images could come together
for one cohesive look.
Once I had settled on the design, I began building my blaster. The core is made of
pieces of scrap melamine we had in the workshop. The details were then built on top
of that with different thicknesses of scrap styrene. The large and small barrel pieces
were made with wood dowels cut in half. The blaster muzzle was made by cutting a
small piece off a piece of aluminum tubing. Everything was glued together with Superglue,
and the process was sped up with a few drops of Superglue Accelerant. The tools I
used were an exacto knife, a dremel, small files, the band saw, and a mouse sander.
Please note: I offer this tutorial to help other costumers build their own prop
blasters. I do not mind at all when girls make a blaster that looks like mine, and
I offer advice to them on a regular basis. This is my personal design, though, so
please do not copy it if you are just planning to mass produce blasters to sell online.
Iíve had that done with my design before, and I was surprised at how much it upset
me. The replica blaster was being sold for more than what I charge for mine, which
I probably could have taken as a compliment... but still, it hurt, and I really donít
want to go through that again.
In this picture the trigger guard is being held on with a piece of tape so that I
could check the fitting. I didn't glue it on permanently until I'd added the trigger,
so that I could have plenty of working room.
The small barrels were the hardest part to make. Filing the low areas between the
sections to look even on both sides of the blaster was a real challenge. It also
took several attempts to shape the trigger correctly and get it glued on in the right
place. Then when I finally did manage to make it look exactly the way I wanted, my
two year old nephew decided to pull the trigger... and snapped it right back off
Once I had finished adding details and sealing the last few gaps with green modeling
putty, I gave the blaster two coats of primer, sanding it with a very fine grit sandpaper
between coats. Then, I gave it a third coating of primer, spraying a very thick layer
this time so that it would build up an interesting texture, which I felt looked better
than the super-smooth plastic look the styrene had given it.
After finishing the blaster and giving it a few coats of sealant, I made a silicone
rubber mold... and I was finally ready to begin casting resin copies of my blaster
If you would like to see a tutorial about how I created this silicone mold, it is
on the Flagship Eclipse website, located here:
To finish a resin casting of the blaster, I started by filling in the little air
bubbles and imperfections in the resin and sanded the repairs smooth. Then I washed
the blaster to remove any traces of oil or dust on the surface, and gave it a coat
of flat black. On top of the black I airbrushed a very light coating of gunmetal,
which gives the blaster a more metallic look and really accents the details.