Next stage was to round off most of the corners on the grips.
Handy tip - having primed the MDF, running the Dremel around the edges was really, really easy to do - hold the Dremel at 45 degrees and keep an eye on the thickness and position of the line of MDF you're cutting into.
After that, sand down with various grades of sandpaper to create the rounded edges...

More coats of primer and sanding...
Then, the question of the little metal bars that go through the bottom of the grips and the small metal domelike button that sits above the trigger had me puzzling for a few days...
Until I realised I could use the cutting and grinding bits of the Dremel to cut the blank bit of a bolt to the length I needed and then grind the ends into domes - easy! (but with lots of baddass sparks)

Finally the construction of the barrels begins - using 15mm and 21.5mm PVC pipe.
Only problem was that I needed an inbetween size too - my solution - Dremel a slot a few millimetres wide down the length of the larger 21.5mm and squeeze it inside the 21.5mm pipe - this will allow me to have a backing for the slots in the barrel as well as connect up the piping to the back of the barrel.

At the business end of the barrel, I realised that the end of a plastic drinks bottle was the same size and slope as a key part of the end of the barrel in the plans, so I'm packing that with a piece of foam and going to build over it with filler.
On the other end - the signature trapezoid shape that holds the barrel to the grip, I'm making out of 5mm Foamex (Sintra.)
After much experimentation I discovered the best way to work was to cut a square of foam, mark up the cutting lines, heat it and bend it around the barrel. That done, I then cut it with a knife and sanded it.
I had tried to pre-cut the trapezoid shape and then bend it, but found that the heating process caused the edges to 'bloom' slightly and the resultant shape looked more 'foamy' with soft edges instead of the precision cut look I wanted.
So, yes, lots of little bits to make, connect up and do, but there's the latest progress on
Nikjay's blasters. And as you can see in the background, we've started work on the helmets too.