I felt that there was a lack of great double barrel nerf blasters and set out to change that. When I began the project, most double barrel blasters fired 1 dart out of each barrel, rather than a true multi-dart shotgun blast.
This project was incredibly successful, and I partnered with OutOfDarts to produce/distribute kits to hobbyists all over the US!
I had a few goals going in to this project, the primary one being that the blaster would be embraced and built by other hobbyists. As such it is much less bespoke than some of my other blaster designs.
This meant that electronics were off of the table. Electronics tend to have a much higher cost and barrier to entry in nerf blasters. This resuulted in a completely mechanical blaster that used a spring-plunger system.
I chose to use the Sillyshell standard for shells since it has grown quite popular in the hobby.
Hardware costs needed to be minimized, with an emphasis on using hardware that was already "hobby standard".
The aesthetics of the blaster need to be meshed with functionality. I wanted to achieve the classic double barrel shotgun look without sacrificing power.
The blaster must eject shells. This is a core part of the experience of the hollywood double barrel shotgun
My release video gives a good overview of how that blaster works and the many smaller features:
The biggest challenge was getting all the blaster features to actuate based on a typical break-action
The mechanics are quite complex, and involve a series of springs, catches, and linkages:
Breaking open the blaster compresses strong springs behind each of the two plungers via a linkage, storing potential energy. The plungers are held in place by a catch
2. Breaking open the blaster compresses strong springs behind each of the two plungers via a linkage, storing potential energy. The plungers are held in place by a catch
3. Shutting the action locks the barrels to the trigger assembly
4. Each barrel can be fired independently by pulling the separate triggers. The triggers push a linkage which releases the catch on each of the plungers.
5. When a plunger is released in rapidly moves forward in its cyclinder, compressing the air. The compressed air travels through a series of integrassted seals and tubes which redirect the air to the rear of the shell
6. After the darts have been fired, pressing the release lever allows the user to break open the action again.
7. As the action moves, the catch for ejector sled is released and the sping is released. This launches the shells out of the barrels
My initial prototype had lots of small issues, but overall was very functional!
I actually completely re-cadded that entire blaster on the second itreration to clean up a lot of messy features and redesign the unlatch mechanism.
I go over some of the details in the video below:
I had also begun to incorporate scrollwork designs into the blaster. The was inspired by boutique real-steel shotguns which feature detailed engraving patterns. These were designed specifically such that theyu could be printed with two different colors with just a simple layer change of filament, no multimaterial printing required.
I was also in the process of documenting the design so that others could build their own.
I created a page on printables with the required print files, a release video, and a drawing package.
You can find the files here:
I partnered with local nerf hobby shop OutOfDarts to help produce and distribute parts for hobbyists looking to build my design.
OutOfDarts supplies hardware kits, full parts kits, and completely assembled blasters, and I get a portion of the sales. Overall, I've sold over 400 kits/blasters/addons related to this project! It's very rewarding to know that there are others out there enjoying my projects.