Okay, so you have the pvc as the barrel, wood for the gun stock. Draw out on paper (to scale) what you want to do. Maybe one centimeter on paper equals one inch on the wood. If you have enough paper you can make it 1:1, so one inch equals one inch. Draw the stock. Then transfer/trace this to the actual wood. Once you have the shape traced on the wood, use the hand saw to cut the basic shape of the rear portion of the gun stock. Get as close as you can but not too close. It's better to not cut off enough than to cut off too much. Now is the long, tedious part. Once the stock is cut out you need to sand to the final shape. Use low number sand paper (~120) to do rough sanding and get it closer to the final shape, higher number (~220) for the final smoothing into the final shape. It'd help if you had a sanding block, but you could just duct tape sand paper to a scrap square/rectangular block of wood and get the same effect. As for attaching the pvc to the wood, I recommend five minute epoxy glue. Sand the edges of the pvc and wood that will touch each other with the rough sandpaper; it'll help give the glue something to grab onto. Apply the glue, apply pressure for five minutes until it sets, let it cure overnight. Then comes staining the wood. You'll have to do a few layers of the stain, then a few of the clear coat i.e. polyurethane. PVC comes in black so that should be good to go.
$30 is too much? The best way to cut down cost is to borrow as much as possible. five minute epoxy is $5, sandpaper is $3-$4 for each 3-pack so $6-$8, wood stain about $5, clear coat $5. $23 plus tax, not including the wood and pvc. If you need to cut down costs, you could try using long, thin nails to attach the pvc to wood rather than glue. Ideally someone else already has one or more of the sand paper, wood stain, clear coat and epoxy/nails items you can borrow, perhaps even the wood board.
Last edited by KillaBeeSwarm : 06-03-2010 at 11:24 AM.