The Colt Model 1911 .45 caliber pistol was the standard semiautomatic sidearm for the USMC and the US Army for generations. Carving a replica with basic shop tools can be a fun and challenging project for a woodworking hobbyist.
Step 1
Select a blank, that is, a piece of suitable lumber large enough to trace or draw out the outline of your pistol. A knotty piece of southern yellow pine at least 12 inches long, 8 inches wide, and 1 inch thick will work well. Note that the knots or gnarly grained wood will not split or crack as easily as a straight grained piece, making your finished gun more rugged.
Step 2
Position the gun (or template, see next step) on the blank so that any large knots fall near the location where the grip meets the action of the weapon. This angle cut through the blank is the weakest area of your project, and as mentioned above, a tight, solid knot will make it stronger.
Step 3
Trace the outline of an actual Colt pistol if you have one available. If you do not have access to one, or a replica like an AirSoft version, you will need to find a photograph of one which can be duplicated to a life sized scale and cut out for a template, or draw one free hand.
Step 4
Draw only the basic outline or shape on the blank, keeping your pencil perpendicular to the edges so you do not get distortion in the actual shape. Make sure the lines are dark enough or contrast the color of the wood well enough to be clearly visible when it is cut.
Step 5
Use a bench top bandsaw with a scrolling woodcutting blade to cut the outline of your pistol out of the blank. Working an inch or so outside the lines at the beginning will allow you to cut very sharp corners more easily, and give you more room to turn the blank on the bandsaw bed (table).
Step 6
After the rough blank is cut out, cut the actual traced line with the bandsaw. You will find it is easier to cut into line intersections beginning at the edge, then remove the blank, and cut an intersecting line rather than trying to make very sharp corners.
Step 7
Rip the stock to the correct width after the blank is cut to the actual shape of the gun. The grips on the Colt should be about 1 1/8 inches thick, the action and barrel about 7/8 inch, but you can leave it a bit thicker so the excess can be sanded away later, when you are finishing the weapon.
Step 8
Use a power sander to round the edges of the grips, the font of the barrel, and the trigger guard, being careful not to remove too much material. A minigrinder, or 4 inch angle grinder with a 60 grit sanding disk on a flexible backing pad works well for this task, but a die grinder or Dremel type tool with a drum sander attachment will also work, and is a bit safer for inexperienced people.
Step 9
Cut the trigger out with a spiral cut saw (Roto-Zip, or die grinder with a spiral cutting bit). Holding the workpiece in a vise makes this process much easier and safer.
Step 10
Use a sharp knife or a carving chisel to cut the recessed areas such as the trigger/trigger guard assembly, the cartridge ejection port, and the taper underneath the barrel near the muzzle. You can also shape the area on the grip where the metal frame and the grip material (usually high impact plastic or hardwood) meet.
Step 11
Use a rasping bit or drum sander on a die grinder to smooth the recesses in the trigger guard, as well as the flats between the grips and the frame. These tools make cutting these irregular and curved surfaces much quicker and easier.
Step 12
Use the die grinder with a cut-off wheel to make the lines in the frame, barrel, and action, as well as cutting any checkering or knurling you want to add to make the gun authentic looking.
Step 13
Use a chisel or carving tool to clean up and finish shape the contours and curves of the frame, action, and barrel of your gun. A very sharp tool will require less force when cutting, reducing the risk of slipping, which can result in a serious injury or damage to the carving.
Step 14
Sand the carving with a medium and then fine grit sandpaper to give a smooth, finished surface. Sanding with (in the direction of) the grain will give the best results.
Tips
- Keep your cutting tools sharp and in good condition.
A variety of tools and accessories will make the different steps easier. - If in doubt, leave the line when making a cut. It is easier to cut a bit more, later, than to try to correct cutting too much.
Warnings
- Do NOT trace around a loaded gun... ever!
- Use care when using power tools.
- Use appropriate safety equipment. A respirator and safety glasses should be worn when shaping/cutting wood with power tools.
- Avoid using chemically treated wood for carving projects.
- Be careful when wielding this replica, as it could be mistaken for a real weapon.
Things You'll Need
- Power tools including either a jigsaw or bandsaw, a sander, and a die-grinder type tool.
- Sandpaper.
- Chisels/carving tools.
- Either a 1911 Colt, a replica, or a good illustration of one.
