The Portal Gun

Or to give it it’s full name, the Aperture Science Handheld Portal Device. Here’s a reference picture of it:

chell

And here’s ours!

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Let me start by saying I would have got absolutely nowhere without these two instructables: Build your own Aperture Science Portal Gun and Budget Portal Gun from Recycled Materials. These were fantastic and I would definitely recommend checking them out before you start.

Obviously we took a little artistic license, but we’re both really pleased with how it turned out!

Let’s start with the tube-y part with the lights in. I’ll do a separate post on the electronics side of it, so if you want to make it with the lights, don’t glue it all together before you plan out your circuits. I used two of these tubes from Lush for the central black part. tubesI think these actually might have been the most expensive part. Anyway, the top and bottom pop off, and the tube opens up flat. I sketched out the shape of the hole I wanted and cut it out of both. I slid one inside the other to strengthen it, make it black both sides, and to leave a space to insert the ‘glass’ cover and run cables back to the hand end from the ‘operational end of the device’. To make one slide into the other, the inner one had to be opened out flat and trimmed down, with also meant I had to make new slots for the tabs to fit, but it worked. a bit of electrical tape over the tabs to secure the join and it was done. I also taped the join on the outer tube to give a clean finish on the outside. I had to trim the ends of the inner tube down too to get the lids back on, but the plastic was easy enough to cut with scissors

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For the glass I tried to find a similar width drinks bottle or something. I actually had one at home that I had in mind to use, but as soon as I wanted it, it disappeared! I couldn’t find a suitable replacement until I realised a cut down 2 litre pop bottle would do the job. It has a ridge in the middle, but I at least made it straight so it looked like it was supposed to be there! It was two wide so I cut a section out and wedged it between the two black tubes, for now. It can be glued in place later after you use it to hide the wiring.

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The central core was a clear plastic handle from a plunger. I really lucked out actually on this as it was cheap from ebay and had two brilliant recesses where I was able to stuff the LEDs rather than trying to light it up from the ends as I saw on instructables, which looked way harder! I sanded the plastic so the lights would be diffused better. It also just happened to be almost the perfect length. For the operational end, I cut through the lid of the tube and used cardboard and craft foam to hold the LEDs in place. The lids are very thick plastic so I had to use a heated needle to punch lots of holes and then sand off the mess. for the back end of the tube I just put a small hole in the lid to fee the wires through, and a hole in the middle to hold the handle/lightstick.

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To bulk up the end I found some guttering parts at B&Q (hardware shop). I think they were kind of brackets. I removed the fixtures and seals and they just about fit right. I decided to cover the LEDs with a thin piece of plastic and foam so it’d look a bit neater.

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The front white piece is the side of a large conditioner bottle, cut down to size and shape. The bottom edge should really have been curved but again we went for time and money saved. The claws I cut from the plastic left over from the black tubes, and glued together with a small piece of craft foam to cover the join and look like a bracket, two on the white part, and one on the top of the black end. I did the same when gluing on the cables, as they’re not functional. In fact I actually glued them into the same bits of craft foam on the claws.

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The back end was two large bleach bottles. I could only find ones with handles so I had to cut those out and overlap the two (hence the big hole!), and cut the top off to fit the black tube in. After it’s all been glued in place, you can use black and white electrical tape to give really nice clean edges. As you can see there’s a whole mess of wiring to figure out too! I put a length of pvc pipe in for a handle so Ethan could easily hold it and still flip the switch.  You can see on the top of the inside of the bottle where the wires lead to the indicator light (the second picture). The indicator was just a small circle cut into the bottle, and I found a curved piece of plastic to cover it, that I stuck in from the inside for neatness. I think it was from a vending machine pod, with a little toy in. I put the tape on for a stripe and then covered the extra glow through the plastic with an aperture logo. This is a visual change I didn’t love to be honest, but it had to be covered or as you can see the glow looked ridiculous. We consoled ourselves by deciding that Ethan was a test subject from before the big GLaDOS meltdown, so the gun was a slightly earlier model than Chell’s!

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You can also see where I used black tape between the bottle and the black tube to neaten it up.

I used the bottom of one of the bottles to give the end a cleaner look, so it wasn’t just the cut off end of the bottle, and cut a hand hole into the bottom for access. A bit of white electrical tape around the edge stopped it being scratchy and looking messy. I also used white tape to cover the joins of the two bottles and neaten it all up.

And there you have it for the physical build! Check out the second post for information about the wiring side of it. Any questions are more than welcome, if I seem to have skipped any steps or you want clarity, comments would be great 🙂

 

 

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