How to Make a Star Wars Clone Trooper Rifle

Use a utility knife or hacksaw (depending on the density of the plastic) to cut away all the parts of the toy rifle, leaving only the stock, grip, trigger and the body. This essentially means cutting off the barrel and any sites or handles on top of the body. You want as low a profile as possible.

Cut the PVC into two lengths for the barrel (30 inches) and the scope (6 inches). Use a hacksaw to cut the PVC.

Using a hacksaw or hand drill, cut out the triangular flanges and site targeting accouterments from the plywood. You are aiming for about 26 inches of wood for the top of the barrel. This can be a rough approximation of the various peaks and valleys attached to the rifle barrel and should be no shorter than 3 inches.

Using a hand drill, cut a 1/8-inch-wide trench down the length of the PVC pipe (about 26 inches) to accommodate the wooden flanges, then insert the flanges into the PVC pipe.

Glue the wooden flanges in place with PVC cement. Allow 4 to 6 hours to dry.

Cut a small slat into the bottom of the barrel, approximately 20 inches from the end of the barrel, using a hand drill. This slot will accommodate the plastic clip.

Insert the clip into the slat, then secure in place with PVC cement. Allow 4 to 6 hours to dry.

Insert the dried barrel into the toy rifle body--where the toy barrel used to be. This might take a bit cajoling. If the toy barrel opening is too small, you can cut a larger hole with a utility knife or hand drill. Once inserted, fix in place with PVC cement and allow 4 to 6 hours to dry.

Attach the 6-inch PVC scope (from Step 2) to the plastic clip attached under the barrel. It should simply snap into place; if it does not, simply glue it in place with PVC cement and allow 4 to 6 hours to dry.

Coat the entire rifle with two coats of black matte spray paint and allow 6 hours to dry.