DENIX MAUSER PREPARATION

 

If you are building a Han Solo Blaster, you have probably purchased a Denix Replica Mauser

These are great for the price, but are not very accurate and lack certain details

This tutorial will demonstrate how to prepare the Denix for conversion

 

*******************DISCLAIMER*******************

Use this tutorial at your own risk. I can not be held responsible for any damage or injury sustained from the improper use of tools or procedures that are outlined below.

******************DISCLAIMER*******************

TOOLS:

  • Pliers
  • Hammer
  • Center Punch
  • Straight Screwdriver
  • Needle Nose Pliers
  • Pedestal Grinder with Wire Wheel Brushes
  • Dremel with attachments
  • Sand Paper
  • Bench Sanders
  • Devcon 5 Minute Epoxy
  • Denatured Alcohol

 

 

1. REMOVING THE LANYARD RING

None of the DL-44 Blasters feature a Lanyard Ring so it must be removed to make the Denix more accurate.
  • Grasp the ring with pliers & twist it off of the frame

 

2. DISASSEMBLING THE DENIX

You will have to disassemble the Denix to convert and clean it. I recommend that you practice this several times until you have mastered the process.

DO NOT REMOVE THE TRIGGER OR HAMMER PINS

THEY ARE VERY DIFFICULT TO REPLACE

 

  • Use a straight screwdriver to remove the Grip Screw (1)
  • Remove the Grip & clean with denatured alcohol
  • Repeat to remove the other Grip
  • Lay the Denix on 2 blocks of wood keeping the Receiver Pin area clear
  • Use a hammer and center punch to drive one Receiver Pin (2) about 1/16" into the Upper Receiver
  • This should push the opposite pin out 1/16"
  • Remove the other Receiver Pin with pliers
  • Remove the Upper Receiver Screw (3) with a Straight Screwdriver
  • You should be able to pull the Upper Receiver from the Lower Receiver
  • Remove the Trigger Stay
  • Use needle nose pliers to remove the other Receiver Pin

 

FROM THE OUTSIDE IT LOOKS LIKE 1 PIN BUT AS YOU CAN SEE IT IS REALLY 2 PINS

 

 

OPTIONAL STEPS TO MAKE THE DENIX MORE ACCURATE

 

 

3. REMOVING THE DENIX LOGO

Do not gouge this depressed area while removing the logo. It is very difficult to fill. Take your time and work slowly.

 

 

  • Use a Dremel with a coarse sanding drum to remove most of the logo

 

 

  • Change over to a sanding flap wheel to finish the removal phase

 

  • Use several grits of sand paper to blend the logo area into the depression.

 

4. CORRECTING THE REAR SIGHT

 

On a real Mauser the Release Button on the Rear Sight Slide points to the right but on a Denix it points to the left. It is easy to correct this, but you must be very careful when you pry the Base Plate off of the Slide. It is held on with pins that are cast as part of it and they will snap easily
  • Carefully pry the Base Plate off of the Sight Slide with a straight screwdriver
  • Flip the Sight Slide so the button points to the right
  • Press the Base Plate on to the Sight slide with pliers
  • Sand the area under the Rear Sight to bare metal
  • Use Devcon 5 Minute Epoxy to secure the sight in place.

If you snapped either Base Plate Pin just use extra epoxy to hold it in place.

 

 

5. REMOVING THE BOLT NUB

Mausers do not have Bolt Nubs. This part is actually the end of a pin that is used to align the Bolt Return Spring

 

 

 

 
  • Hit the Bolt Nub with a hammer to make sure it is tight
  • Remove the Nub with a Bench Belt Sander
  • Finish the area with a fine belt on a Combo Sander

 

 

6. REMOVING THE SAFETY

ATTENTION :The Safety was removed on the ROTJ version ONLY
  • Use a Dremel to cut off the Safety

  • Shape the area with a Combo Sander

 

 

7. REASSEMBLING THE DENIX

This is done by reversing the disassembly steps, but you must be careful when you drive the Upper Receiver pins in place or you may bend them.

  • Cock the Hammer, you may have to pull the trigger so that the Hammer Catch can engage the Hammer Notch
  • Set the Trigger Stay in place
  • Set the Upper Receiver in place
  • Align the Upper and Lower Receiver Pin holes
  • Drive the left & right Receiver Pins though the Upper Receiver and into the Lower Receiver
  • Replace the Upper Receiver screw
  • If the Bolt will not operate properly loosen the Upper Receiver Screw Slightly until it does

 

8. CLEANING THE DENIX

No matter how careful you are you will damage the cheap coating that comes on the Denix. It is best to clean and wire brush it so that it will accept paint better when the time comes

ATTENTION :DO NOT BUFF OR SAND BLAST THE METAL BECAUSE IT WILL NOT TAKE PAINT IF YOU DO

  • Carefully Wire Brush the entire Denix
  • Clean it several times with denatured alcohol
  • Replace the Plastic Grips
YOU HAVE JUST PREPARED YOUR DENIX