Adding the features Nerf Neglected (Part One)

 Anyone who knew me growing up knows that I love Halo.  As such, it should come as no surprise to them that I was greatly excited by the news of Microsoft and Nerf partnering to release Halo-themed Nerf blasters this holiday season.  As soon as I could, I preorder the Nerf Halo MA40 Assault Rifle.  It came in the mail a few days ago, and I was slightly disappointed at the surprising lack of features that the blaster came with.  Overall, the shape, size, and paint job of the blaster was very good.  However, it lacked a few features that prevent it from being the ideal Nerf Halo assault rifle.  These features include:  A reciprocating dummy charging handle, a functioning flashlight, and a functioning ammo counter.  This post will deal with the first modification I made to the blaster: the charging handle.  What follows is a tutorial for this modification.

If you would like to purchase the stock blaster this modification is designed for, it can be found here:  Amazon 

The model files for this modification can be downloaded here:  Drive

This assembly replaces the static charging handle on the Nerf Halo MA40 assault rifle with one that moves.  In order to install it, you will need a drill and 19/64 inch drill bit, a Dremel with a cutting wheel, a small circular file, a small flat file, and a screwdriver to disassemble the blaster. 

 

The other required parts are a small spring and 3 small screws (1 wide headed and 2 normal).  I just grabbed these parts from my misc. parts drawer, but once I put a kit together I will give more specifics for which parts work best.

 

In order to install this, skill with a Dremel will be very helpful.  The design does allow for some small mistakes to be made, but the better you are at cutting the better this part will fit and look.

 

First, disassemble the blaster and remove the orange charging handle from the side.

 Then, carefully drill out the right corner of the molded channel for the dummy charging handle using the drill and 19/64 inch drill bit.  Make a few more holes along the channel .  The holes should be centered vertically as best as possible.  Do not attempt to drill out the left side.  The slot for the old charging handle will make this too complicated, so it is best to just use the Dremel to cut out that side. 

 

Next, use the Dremel to connect the holes down the length of the charging handle.  Be careful not to cut too much out from the top and bottom of the channel.  You want to cut out just up until the edge of the molding of the channel.  If you are not confident in your Dremel skills, then leave a few mm between the cut and the channel's edge.  You should also use the Dremel to make some initial cuts on the left side where the old charging handle was.  Do not get too close to the far left edge unless you have very steady hands.

 

After that, use the files to correct any mistakes from the Dremel cuts.  The circular file should be used to finish off the left side, and the flat file should be used to make the top and bottom edges straight.

 

If all went well, then your shell modification should be done.  Now on to the installation. 

 

First, print out and glue the charging handle guide into the hole you just made.  The guide installs from the outside of the blaster, and the circular post should go on the side closest to the muzzle of the blaster.  If the hole is not big enough, carefully use the file to enlarge it.  Take things slow.  You don't want to make the hole too big.

 

Next, print the charging handle and the inside piece.  The charging handle goes into the guide from the outside of the blaster.  You might have to file down the supports and a bit of the surfaces that slide against the guide.  Once the charging handle is sitting on the guide, flip the shell over to the other side, being careful to make sure the charging handle stays in place. 

 

Now, place the spring onto the post of the guide and use the wide-headed screw to secure it in place. 

 

Next, stretch the spring to the closest post on the inside of the handle. 

 

After that, push the inside piece onto the posts, being sure to line up the side with the cutout with the post that has the spring connected.  Screw the remaining two screws into the two holes on the inside piece.

 

Now, just reassemble the blaster, and you're finished!

 

I had an issue where the post of the guide piece broke off.  If you run into this issue, there is an easy fix that is much sturdier.  Simply locate and drill out the small circular indentation to the left of the charging handle.  Then, use a nut and bolt to secure the return spring through the hole.  This method is sturdier, but it is more visible on the finished blaster.  I used PLA for my pieces, but ABS might be sturdy enough to handle it.

Here are a couple of views of it working: